Insulated container

ABSTRACT

A container is formed to include an interior region and a mouth opening into the interior region. The container includes a floor and a side wall coupled to the floor to define the interior region between the floor and the side wall.

PRIORITY CLAIM

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Application Ser. No. 61/498,455, filed Jun. 17, 2011 andSer. No. 61/618,587, filed Mar. 30, 2012, which are expresslyincorporated by reference herein.

BACKGROUND

The present disclosure relates to vessels, and in particular toinsulated containers, such as cups, for containing hot or cold beveragesor food. More particularly, the present disclosure relates to aninsulated cup formed from polymeric materials.

SUMMARY

A vessel in accordance with the present disclosure is configured to holda product in an interior region. In illustrative embodiments, the vesselis an insulated container such as a drink cup, a food-storage cup, or adessert cup.

In illustrative embodiments, an insulative cup includes a body having asleeve-shaped side wall and a floor coupled to the body to cooperatewith the side wall to form an interior region for storing food, liquid,or any suitable product. The body also includes a rolled brim coupled toan upper end of the side wall and a floor mount coupled to a lower endof the side wall and to the floor.

In illustrative embodiments, the body is made of a sheet comprising aninsulative cellular non-aromatic polymeric material. In some embodimentsof the present disclosure, the body is made of a multi-layer sheetincluding a substrate layer comprising the insulative cellularnon-aromatic polymeric material and an outer layer comprising a skincoupled to the substrate layer and configured to display artwork andtext. In other embodiments of the present disclosure, such text andartwork are printed directly on an exterior surface of the insulativecellular non-aromatic polymeric material. In illustrative embodiments,the floor also comprises insulative cellular non-aromatic polymericmaterial.

The insulative cellular non-aromatic polymer material included in thebody is configured in accordance with the present disclosure to providemeans for enabling localized plastic deformation in at least oneselected region of the body (e.g., the side wall, the rolled brim, thefloor mount, and a floor-retaining flange included in the floor mount)to provide (1) a plastically deformed first material segment having afirst density in a first portion of the selected region of the body and(2) a second material segment having a relatively lower second densityin an adjacent second portion of the selected region of the body. Inillustrative embodiments, the more dense first material segment isthinner than the second material segment.

In illustrative embodiments, the insulative cellular non-aromaticpolymeric material comprises a polypropylene base resin having a highmelt strength, a polypropylene copolymer or a homopolymer resin (orboth), and cell-forming agents including primary and secondarynucleating agents and a blowing agent such as carbon dioxide gas that isinjected into the resins to expand the resins and reduce density. Thebase resin comprises broadly distributed molecular weight polypropylenecharacterized by a distribution that is unimodal (not bimodal).

In illustrative embodiments, the skin is coupled to an exterior surfaceof the insulative cellular non-aromatic polymeric material. The skinincludes a film, an adhesive interposed between the film and theexterior surface of the insulative cellular non-aromatic polymericmaterial, and an ink printed on the film to provide a graphic designincluding artwork, text, or both. The film is biaxially orientedpolypropylene in illustrative embodiments.

Additional features of the present disclosure will become apparent tothose skilled in the art upon consideration of illustrative embodimentsexemplifying the best mode of carrying out the disclosure as presentlyperceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figuresin which:

FIG. 1 is a perspective view of an insulative cup in accordance with thepresent disclosure showing that the insulative cup includes a body and afloor and showing that four regions of the body include localized areasof plastic deformation that provide for increased density in those areaswhile maintaining a predetermined insulative characteristic in the body;

FIG. 1A is an enlarged sectional view of a portion of a side wallincluded in the body of the insulative cup of FIG. 1 showing that theside wall is made from a sheet that includes, from left to right, askin, an ink layer, an adhesive layer, and insulative cellularnon-aromatic polymer material;

FIG. 2 is an exploded assembly view of the insulative cup of FIG. 1showing that the insulative cup includes, from top to bottom, the floorand the body including a rolled brim, the side wall, and a supportstructure configured to mate with the floor as shown in FIG. 1;

FIG. 3 is a sectional view taken along line 3-3 of FIG. 2 showing thatthe side wall included in the body of the insulative cup includes agenerally uniform thickness and showing that the floor is coupled to afloor mount included in the body;

FIGS. 3A-3D are a series of views showing first, second, third, andfourth regions of the insulative cup of FIG. 1 that each includelocalized plastic deformation;

FIG. 3A is a partial section view taken along line 3-3 of FIG. 1 showingthe first region is in the side wall of the body;

FIG. 3B is a partial section view taken along line 3-3 of FIG. 1 showingthe second region is in the rolled brim of the body;

FIG. 3C is a partial section view taken along line 3-3 of FIG. 1 showingthe third region is in a connecting web included in the floor mount ofthe body;

FIG. 3D is a partial section view taken along line 3-3 of FIG. 1 showingthe fourth region is in a web-support ring included in the floor mountof the body;

FIG. 4 is a dead section view taken along line 4-4 of FIG. 1 showingthat the side wall of the insulative cup includes a C-shaped fence, anupright outer tab coupled to one end of the C-shaped fence, and anupright inner tab coupled to an opposite end of the C-shaped fence andsuggesting that the first and second tabs are arranged to overlap oneanother to establish a bridge extending between the ends of the C-shapedfence to define the interior region therebetween;

FIG. 4A is an enlarged dead section view of a bridge in accordance withthe present disclosure showing how the insulative cellular non-aromaticpolymer material has been compressed in both the first and second tabsto produce a bridge having a reduced thickness that is similar to athickness of the side wall in the C-shaped fence opposite the bridge;

FIG. 4B is an enlarged dead section view of a portion of the C-shapedfence of FIG. 4A showing that the insulative cellular non-aromaticpolymer material has not been compressed;

FIG. 4C is an enlarged dead section view of the first and second tabsprior to mating to one another to establish the bridge;

FIG. 5 is an enlarged view similar to FIG. 4A;

FIG. 6 is diagrammatic and dead section view of the rolled brim of FIGS.1, 3, and 3B showing the second region of localized plastic deformation;

FIG. 6A is a partial sectional view of a combination of the insulativecup of FIG. 1 and a lid showing that the lid includes a rim that mateswith the rolled brim of the insulative cup as suggested in FIG. 6B;

FIG. 6B is a partial sectional view of the lid and insulative cup ofFIG. 5 with the lid mated to the cup so that the rim of the lid engagesthe rolled brim of the insulative cup to close a mouth opening into theinterior region;

FIG. 7 is an enlarged partial elevation view of the insulative cup ofFIGS. 1, 3, and 3C showing that the floor is coupled to the side wall bythe floor mount and that the floor mount includes a web-support ringcoupled to the side wall, a floor-retaining flange radially spaced-apartfrom the web-support ring, and a connecting web interconnecting theweb-support ring and the floor-retaining flange;

FIG. 7A is a dead section view of a portion of an insulative cup inaccordance with the present disclosure showing the third region oflocalized plastics deformation of the insulative cellular non-aromaticpolymer material in the connecting web of the floor mount and showingmelting of the insulative cellular non-aromatic polymer material alongan interface between the floor-retaining flange and a portion of thefloor;

FIG. 8 is an enlarged view similar to FIG. 7A;

FIG. 9 is an enlarged partial elevation view of the insulative cup ofFIGS. 1, 3 and 3D showing the fourth region of localized plasticdeformation is formed in the floor-retaining flange and includeschannels formed between neighboring thick sections of thefloor-retaining flange;

FIG. 9A is a view similar to FIG. 3D showing alternating thick and thinsections of the floor-retaining flange;

FIG. 9B is a dead section view of a portion of a floor-retaining flangein accordance with the present disclosure showing that a channel isformed between two neighboring thick sections of the floor-retainingflange;

FIG. 10 is an enlarged view similar to FIG. 9B;

FIG. 11 is an enlarged view of the channel of FIG. 10 showing that theinsulative cellular non-aromatic polymeric material is formed to includecells filled with gas, that each cell is bounded by a cell wall that isshared with neighboring cells, and that the cell walls are deformedduring a cup-forming process suggested in FIGS. 15-19 to cause densityto be increased in the area of localized plastic deformation;

FIG. 12A is a plan view of a body blank used to make the body of FIG. 1with portions broken away to reveal that the body blank is formed from astrip of insulative cellular non-aromatic polymeric material and a skinlaminated to the strip of insulative cellular non-aromatic polymericmaterial and suggesting that during a blank forming process a web formercompresses a portion of the body blank along an arcuate fold line toform the connecting web and a stave former compresses another portion ofthe body blank between the arcuate fold line and a lower arcuate edge toform a series of alternating thick and thin staves that extend betweenthe arcuate fold line and the second lower arcuate edge;

FIG. 12B is a view similar to FIG. 12A after the blank forming processhas been performed showing that both the connecting web and the staveshave been formed in the body blank;

FIG. 12C is a plan view of another embodiment of a body blank inaccordance with the present disclosure showing that the body blank isformed from a sheet that includes only insulative cellular non-aromaticpolymeric material;

FIG. 13 is an enlarged partial plan view of the side-wall blank of FIG.12B showing the arcuate fold line and alternating thick and thin staveswhich cooperate to define channels in the floor-retaining flange;

FIG. 14 is a dead section view taken along line 14-14 of FIG. 13 showinga number of channels formed between neighboring pairs of thick sectionsof a floor-retaining flange included in the side-wall blank;

FIG. 15 is a graph showing performance over time of insulative cups inaccordance with the present disclosure undergoing temperature testing;

FIG. 16 is a perspective and diagrammatic view of a cup-manufacturingprocess in accordance with the present disclosure showing that thecup-manufacturing process includes providing a laminated roll oflaminated sheet, forming an insulative cup as suggested in detail inFIGS. 17-19, and packaging stacks of insulative cups as suggested indetail in FIG. 20 and showing that forming an insulative cup includesthe steps of forming a body blank as suggested in detail in FIG. 17,annealing the body blank, forming a cup base as suggested in detail inFIG. 18, and forming a rolled brim as suggested in detail in FIG. 19;

FIG. 17 is a perspective and diagrammatic view of the body blank formingstage showing that the body blank forming stage includes the steps ofloading the laminated roll to provide the laminated sheet, annealing thelaminated sheet, compressing the laminated sheet to form a compressedsheet, cutting the compressed sheet to form body blanks and scrap,collecting scrap, and accumulating the body blanks to form body blankstacks;

FIG. 18 is a perspective and diagrammatic view of the cup-base formingstage showing that the cup-base forming stage includes the steps ofloading body blank stacks, heating the body blank, wrapping the bodyblank around a mandrel, forming a body, loading another laminated rollto provide the laminated sheet, cutting the laminated sheet to providefloor blanks and scrap, shaping the floor blanks into a floor, heatingthe floor, heating the body, wrapping the body around the floor, andcoupling the floor to the base to establish a cup body;

FIG. 19 is a perspective and diagrammatic view of the brim-forming stageshowing that the brim-forming stage includes the steps of transferringthe cup base to a brim-forming machine, optionally lubricating the topportion of the base, heating the top portion of the base, and rollingthe top portion of the base to form an insulative cup having a rolledbrim;

FIG. 20 is a perspective and diagrammatic view of the cup-packagingstage showing that the cup-packaging stage includes the steps ofinspecting the insulative cup for leaks, accumulating the good cups toform stacks of insulative cups, and packaging the stacks of insulativecups for storage and transportation;

FIG. 21 is a plan view of another embodiment of a body blank inaccordance with the present disclosure showing that the body blankincludes a first upper arcuate edge, a second lower arcuate edge, anarcuate fold line therebetween, a series of spaced apart channelsextending between the arcuate fold line and the second lower arcuateedge, and including brim tabs that are compressed to reduce thethickness of the insulative cellular non-aromatic polymeric materialwhere portions of the body blank overlap to form a rolled brim;

FIG. 22 is a sectional view taken along line 22-22 of FIG. 21;

FIG. 23 is a plan view of yet another embodiment of a body blank inaccordance with the present disclosure showing that the body blankincludes a first upper arcuate edge, a second lower arcuate edge, anarcuate fold line therebetween, a series of spaced apart channelsextending between the arcuate fold line and the second lower arcuateedge, and first and second tabs that have been compressed prior to bodyforming to reduce the thickness of the material where portions of thebody blank overlap to form a bridge;

FIG. 24 is a sectional view taken along line 24-24 of FIG. 23;

FIG. 25 is a perspective view of another embodiment of an insulative cupin accordance with the present disclosure showing that the insulativecup includes a body including a rolled brim, a side wall, and a floormount and a floor coupled to both the support structure and the bottomportion of the side wall and showing that portions of the side wall havebeen compressed to form a number of ribs extending outwardly away fromthe compressed portions of the side wall;

FIG. 26 is a plan view of the body blank used to form the body of theinsulative cup shown in FIG. 25 showing that the body blank includes afirst upper arcuate edge, a second lower arcuate edge, an arcuate foldline therebetween, a series of spaced apart channels extending betweenthe arcuate fold line and the second lower arcuate edge, and compressedportions of the side wall that establish ribs therebetween to reduce thesurface area of contact between the hand of a user and the outer surfaceof the cup;

FIG. 27 is a sectional view taken along line 27-27 of FIG. 26;

FIG. 28 is a perspective view of yet another embodiment of an insulativecup in accordance with the present disclosure showing that theinsulative cup includes a body including a rolled brim, a side wall, anda floor mount and a floor coupled to both the support structure and thebottom portion of the side wall and showing a number of protruding ribsformed in the side wall as a result of displacing portions of the sidewall;

FIG. 29 is a plan view of a body blank used to make the body of theinsulative cup shown in FIG. 28 showing that the body blank includes afirst upper arcuate edge, a second lower arcuate edge, an arcuate foldline therebetween, a series of spaced apart channels extending betweenthe arcuate fold line and the second lower arcuate edge, and protrudingribs formed as a result of displacing material to form ribs that areused to reduce the surface area of contact between the hand of a userand the outer surface of the cup;

FIG. 30 is a sectional view taken along line 30-30 of FIG. 29;

FIG. 31 is an enlarged portion of FIG. 30 showing that material has beendisplaced in the side wall to form the rib;

FIG. 32 is a dead section view of another embodiment of a rolled brim inaccordance with the present disclosure showing that the rolled brim hasa generally constant thickness throughout;

FIG. 33 is a dead section view of yet another embodiment of a rolledbrim in accordance with the present disclosure showing that the rolledbrim includes a thickness that becomes relatively thinner toward a freeend of the rolled brim;

FIG. 34 is a dead section view of yet another embodiment of a rolledbrim in accordance with the present disclosure showing that the rolledbrim has been rolled upon itself so that generally no space is formed inthe rolled brim;

FIG. 35 is an enlarged partial elevation view of another embodiment ofan insulative cup in accordance with the present disclosure showing afourth region of localized plastic deformation in which channels areformed in an inner periphery of the floor-retaining flange so that thechannels are hidden when the insulative cup is assembled;

FIG. 36 is an enlarged partial elevation view of the floor similar toFIG. 35 showing the floor mating with a floor mount included in theinsulative cup and that the channels are spaced apart from one another,the connecting web, and the floor;

FIG. 37 is a view similar to FIG. 1A showing an embodiment of a sheetthat includes, from top to bottom, a skin including a film, an inklayer, an adhesive layer, and a strip of insulative cellularnon-aromatic polymeric material; and

FIG. 38 is a view similar to FIG. 37 showing another embodiment of asheet that includes, from top to bottom, an outer skin including a film,an ink layer, and an adhesive layer, a strip of insulative cellularnon-aromatic polymeric material, and an inner skin including a film, anink layer, and an adhesive layer.

DETAILED DESCRIPTION

Localized plastic deformation is provided in accordance with the presentdisclosure in, for example, four regions 101, 102, 103, and 104 of abody 11 of an insulative cup 10 comprising an insulative cellularnon-aromatic polymeric material as suggested in FIGS. 1 and 3-3D. Amaterial has been plastically deformed, for example, when it has changedshape to take on a permanent set in response to exposure to an externalcompression load and remains in that new shape after the load has beenremoved. Insulative cup 10 disclosed herein is not a paper cup butrather a cup made of a cellular non-aromatic polymeric material withinsulative qualities suitable for holding hot and cold contents.

A first embodiment of an insulative cup 10 having four regions 101-104where localized plastic deformation provides segments of insulative cup10 that exhibit higher material density than neighboring segments ofinsulative cup 10 in accordance with the present disclosure is shown inFIGS. 1 and 2-11. As an example, insulative cup 10 is made using anillustrative body blank 500 shown in FIGS. 12-14. A cup-manufacturingprocess 40 that makes body blank 500 and insulative cup 10 is shown inFIGS. 16-20. Other embodiments of body blanks 800, 820, 836, and 856 inaccordance with the present disclosure that may be used to forminsulative cups are illustrated in FIGS. 21-31. Rolled brims 16A, 16B,16C that may be used with various insulative cups are illustrated inFIGS. 32-34. A first embodiment of an insulative cellular non-aromaticpolymeric material used to form insulative cup 10 is shown in FIGS. 1Aand 37. Another embodiment of an insulative cellular non-aromaticpolymeric material in accordance with the present disclosure is shown inFIG. 38.

An insulative cup 10 comprises a body 11 including a sleeve-shaped sidewall 18 and a floor 20 coupled to body 11 to define an interior region14 bounded by sleeve-shaped side wall 18 and floor 20 as shown, forexample, in FIG. 1. Body 11 further includes a rolled brim 16 coupled toan upper end of side wall 18 and a floor mount 17 coupled to a lower endof side wall 18 as suggested in FIGS. 1-3.

Body 11 is formed from a strip of insulative cellular non-aromaticpolymeric material as disclosed herein. In accordance with the presentdisclosure, a strip of insulative cellular non-aromatic polymericmaterial is configured (by application of pressure—with or withoutapplication of heat) to provide means for enabling localized plasticdeformation in at least one selected region (for example, regions101-104) of body 11 to provide a plastically deformed first materialsegment having a first density located in a first portion of theselected region of body 11 and a second material segment having a seconddensity lower than the first density located in an adjacent secondportion of the selected region of body 11 without fracturing theinsulative cellular non-aromatic polymeric material so that apredetermined insulative characteristic is maintained in body 11.

A first region 101 of the selected regions of body 11 in which localizedplastic deformation is enabled by the insulative cellular non-aromaticpolymeric material is in sleeve-shaped side wall 18 as suggested inFIGS. 1, 3A, and 4. Sleeve-shaped side wall 18 includes an upright innertab 514, an upright outer tab 512, and an upright fence 513 extendingbetween inner and outer tabs 514, 512 as suggested in FIGS. 1, 3, and 4.Upright inner tab 514 is arranged to extend upwardly from floor 20 andconfigured to provide the first material segment having the higher firstdensity in the first region 101 of the selected regions of body 11.Upright outer tab 512 is arranged to extend upwardly from floor 20 andto mate with upright inner tab 514 along an interface I therebetween assuggested in FIG. 4. Upright fence 513 is arranged to interconnectupright inner and outer tabs 514, 512 and surround interior region 14.Upright fence 513 is configured to provide the second material segmenthaving the lower second density in the first region 101 of the selectedregions of body 11 and cooperate with upright inner and outer tabs 514,512 to form sleeve-shaped side wall 18 as suggested in FIGS. 3 and 4.

A second region 102 of the selected regions of body 11 in whichlocalized plastic deformation is enabled by the insulative cellularnon-aromatic polymeric material is in a rolled brim 16 included in body11 as suggested in FIGS. 1, 3B, and 6. Rolled brim 16 is coupled to anupper end of sleeve-shaped side wall 18 to lie in spaced-apart relationto floor 20 and to frame an opening into interior region 14. Rolled brim16 includes an inner rolled tab 164, an outer rolled tab 162, and arolled lip 163 as suggested in FIGS. 1, 3, and 6. Inner rolled tab 164is configured to provide the first material segment having the higherfirst density in the second region 102 of the selected regions of body11. Inner rolled tab 164 is coupled to an upper end of upright outer tab512 included in sleeve-shaped side wall 18. Outer rolled tab 162 iscoupled to an upper end of upright inner tab 514 included insleeve-shaped side wall 18 and to an outwardly facing exterior surfaceof inner rolled tab 164. Rolled lip 163 is arranged to interconnectoppositely facing side edges of each of inner and outer rolled tabs 164,162. Rolled lip 163 is configured to provide the second material segmenthaving the lower second density in the second 102 of the selected regionof body 11 and cooperate with inner and outer rolled tabs 164, 162 toform rolled brim 16 as suggested in FIG. 1.

A third region 103 of the selected regions of body 11 in which localizedplastic deformation is enabled by the insulative cellular non-aromaticpolymeric material is in a floor mount 17 included in body 11 assuggested in FIGS. 1, 3C, 7, and 7A. Floor mount 17 is coupled to alower end of sleeve-shaped side wall 18 to lie in spaced-apart relationto rolled brim 16 and to floor 20 to support floor 20 in a stationaryposition relative to sleeve-shaped side wall 18 to form interior region14. Floor mount 17 includes a web-support ring 126, a floor-retainingflange 26, and a connecting web 25 extending between web-support ring126 and floor-retaining flange 26 as suggested in FIG. 3. Web-supportring 126 is coupled to the lower end of sleeve-shaped side wall 18 andconfigured to provide the second material segment having the lowersecond density in the third region 103 of the selected regions of body11. Floor-retaining flange 26 is coupled to floor 20 and arranged to besurrounded by web-support ring 126 as suggested in FIG. 3. Connectingweb 25 is arranged to interconnect floor-retaining flange 26 andweb-support ring 126. Connecting web 25 is configured to provide thefirst material segment having the higher first density in the thirdregion 103 of the selected regions of body 11. Connecting web 25 ispreformed in a body blank 500 in an illustrative embodiment before bodyblank 500 is formed to define insulative cup 10 as suggested in FIGS.16-20.

A fourth region 104 of the selected regions of body 11 in whichlocalized plastic deformation is enabled by the insulative cellularnon-aromatic polymeric material is in floor-retaining flange 26 of floormount 17 as suggested in FIGS. 1, 3D, 9, 9A, and 9B. Floor-retainingflange 26 includes an alternating series of upright thick and thinstaves arranged in side-to-side relation to extend upwardly fromconnecting web 25 toward interior region 14 bounded by sleeve-shapedside wall 18 and floor 20. This alternating series of thick and thinstaves is preformed in a body blank 500 in an illustrative embodimentbefore body blank 500 is formed to define insulative cup 10 as suggestedin FIGS. 16-20. As suggested in FIG. 7, a first 261 of the upright thickstaves is configured to include a right side edge 261R extendingupwardly from web 25 toward interior region 14. A second 262 of theupright thick staves is configured to include a left side edge 262Larranged to extend upwardly from web 25 toward interior region 14 andlie in spaced-apart confronting relation to right side edge 261R of thefirst 261 of the upright thick staves. A first 260 of the upright thinstaves is arranged to interconnect right side edge 261R of the first 261of the upright thick staves and left side edge 262L of the second 262 ofthe upright thick staves and to cooperate with left and right side edges262L, 261R to define therebetween a vertical channel 263 openinginwardly into a lower interior region 264 bounded by floor-retainingflange 26 and a horizontal platform 21 included in floor 20 and locatedabove floor-retaining flange 26 as suggested in FIG. 7. The first 260 ofthe upright thin staves is configured to provide the first materialsegment having the higher first density in the fourth region 104 of theselected regions of body 11. The first 261 of the upright thick stavesis configured to provide the second material segment having the lowersecond density in the fourth region 104 of the selected regions of thebody 11.

Sleeve-shaped side wall 18 of body 11 includes a pair of tabs 514, 512that mate to provide side wall 18 with a frustoconical shape in theillustrative embodiment shown in FIGS. 1, 3, 3A, and 4. Upright innertab 514 of side wall 18 includes an inner surface 514 i bounding aportion of interior region 14 and an outer surface 514 o facing towardupright outer tab 512 as shown in FIGS. 4 and 4C. Upright outer tab 512includes an inner surface 512 i facing toward interior region 14 andmating with outer surface 514 o of upright inner tab 514 to define theinterface I between upright inner and outer tabs 514, 512. Upright outertab 512 further includes an outer face 512 o facing away from uprightinner tab 514. Each of inner and outer surfaces of upright inner andouter tabs 514, 512 has an arcuate shape in a horizontal cross-sectionas suggested in FIG. 4C and subtends an acute angle of less than 20° assuggested in FIG. 4.

Upright fence 513 of side wall 18 is C-shaped in a horizontalcross-section and each of upright inner and outer tabs 514, 512 has anarcuate shape in a horizontal cross-section as suggested in FIG. 4.Upright fence 513 includes an upright left side edge 513L and an uprightright side edge 513R that is arranged to lie in spaced-apart confrontingrelation to upright left side edge 513L in FIG. 4C. Upright outer tab512 is configured to have the higher first density and mate with uprightinner tab 514 also characterized by the higher first density toestablish a bridge 512, 514 arranged to interconnect upright left andright side edges 513L, 513R of upright fence 513. Bridge 512, 514 isformed of plastically deformed material having the higher first density.

Upright fence 513 of side wall 18 has an inner surface 513 i bounding aportion of interior region 14 and an outer surface 513 o facing awayfrom interior region 14 and surrounding inner surface 513 i of uprightfence 513 as shown, or example, in FIG. 4. Outer surface 513 ocooperates with inner surface 513 i of upright fence 513 to define afirst thickness T1 therebetween. Upright inner tab 514 includes an innersurface 514 i bounding a portion of interior region 14 and an outersurface 514 o facing toward upright outer tab 512. Upright outer tab 512includes an inner surface 512 i facing toward interior region 14 andmating with outer surface 514 o of upright inner tab 514 to define theinterface I between upright inner and outer tabs 514, 512. Upright outertab 512 further includes an outer face 512 o facing away from uprightinner tab 514. Inner and outer surfaces of upright inner tab 514cooperate to define a second thickness T2I therebetween that is lessthan the first thickness T1. Inner and outer surfaces of upright outertab 512 cooperate to define a third thickness T2O that is less than thefirst thickness T1.

Rolled brim 16 of body 11 is coupled to an upper end of sleeve-shapedside wall 18 to lie in spaced-apart relation to floor 20 and to frame anopening into interior region 14 as suggested in FIGS. 1 and 3B. Innerrolled tab 164 of rolled brim 16 is configured to provide theplastically deformed first material segment having the higher firstdensity and to include oppositely facing left and right side edges.Rolled lip 163 of rolled brim 16 is arranged to interconnect theoppositely facing left and right side edges of inner rolled tab 164 andconfigured to provide the second material segment having the lowersecond density. Outer rolled tab 162 of rolled brim 16 is coupled to anoutwardly facing surface of inner rolled tab 164 as suggested in FIG. 1to provide an outer shell covering inner rolled tab 164 and formed ofplastically deformed material having the higher first density. Outerrolled tab 162 includes oppositely facing left and right side edges.Rolled lip 163 is arranged to interconnect the oppositely facing leftand right side edges of outer rolled tab 162. Rolled lip 163 is C-shapedin horizontal cross-section. Each of inner and outer rolled tabs 164,162 has an arcuate shape between the oppositely facing left and rightside edges thereof to provide rolled brim 16 with an annular shape.

Floor mount 17 of body 11 is coupled to a lower end of sleeve-shapedside wall 18 and to floor 20 to support floor 20 in a stationaryposition relative to sleeve-shaped side wall 18 to form interior region14 as suggested in FIGS. 1-3 and 3C. Floor mount 17 includes afloor-retaining flange 26 coupled to floor 20, a web-support ring 126coupled to the lower end of sleeve-shaped side wall 18 and arranged tosurround floor-retaining flange 26, and a connecting web 25 arranged tointerconnect floor-retaining flange 26 and web-support ring 126 assuggested in FIG. 3C. Connecting web 25 is configured to provide thefirst material segment having the higher first density. Connectingweb-support ring 126 is configured to provide the second materialsegment having the lower second density. Each of connecting web 25 andweb-support ring 126 has an annular shape. Floor-retaining flange 26 hasan annular shape. Each of floor-retaining flange 26, connecting web 25,and web-support ring 126 includes an inner layer having an interiorsurface mating with floor 20 and an overlapping outer layer mating withan exterior surface of inner layer as suggested in FIGS. 3 and 7.

Floor 20 of insulative cup 10 includes a horizontal platform 21 boundinga portion of interior region 14 and a platform-support member 23 coupledto horizontal platform 21 as shown, for example, in FIGS. 2 and 3C.Platform-support member 23 is ring-shaped and arranged to extenddownwardly away from horizontal platform 21 and interior region 14 intoa space 27 provided between floor-retaining flange 26 and theweb-support ring 126 surrounding floor-retaining flange 26 to mate witheach of floor-retaining flange 26 and web-support ring 126 as suggestedin FIGS. 3 and 7.

Platform-support member 23 of floor 20 has an annular shape and isarranged to surround floor-retaining flange 26 and lie in an annularspace provided between horizontal platform 21 and connecting web 25 assuggested in FIGS. 3, 3C, and 3D. Each of floor-retaining flange 26,connecting web 25, and web-support ring 126 includes an inner layerhaving an interior surface mating with floor 20 and an overlapping outerlayer mating with an exterior surface of inner layer as suggested inFIGS. 3 and 6. Inner layer of each of floor-retaining flange 26, web 25,and web-support ring 126 is arranged to mate with platform-supportmember 23 as suggested in FIG. 3C.

Floor-retaining flange 26 of floor mount 17 is arranged to lie in astationary position relative to sleeve-shaped side wall 18 and coupledto floor 20 to retain floor 20 in a stationary position relative tosleeve-shaped side wall 18 as suggested in FIGS. 3, 3C, and 7.Horizontal platform 21 of floor 20 has a perimeter edge mating with aninner surface of sleeve-shaped side wall 18 and an upwardly facing topside bounding a portion of interior region 14 as suggested in FIGS. 3and 3C.

Floor-retaining flange 26 of floor mount 17 is ring-shaped and includesan alternating series of upright thick and thin staves arranged to liein side-to-side relation to one another to extend upwardly toward adownwardly facing underside of horizontal platform 21. A first 261 ofthe upright thick staves is configured to include a right side edge 261Rextending upwardly toward the underside of horizontal platform 21. Asecond 262 of the upright thick staves is configured to include a leftside edge 262L arranged to extend upwardly toward underside ofhorizontal platform 21 and lie in spaced-apart confronting relation toright side edge 261R of the first 261 of the upright thick staves. Afirst 260 of the upright thin staves is arranged to interconnect leftand right side edges 262L, 261R and cooperate with left and right sideedges 262L, 261R to define therebetween a vertical channel 263 openinginwardly into a lower interior region 264 bounded by horizontal platform21 and floor-retaining flange 26 as suggested in FIGS. 3D, 7, and 9. Thefirst 260 of the thin staves is configured to provide the first materialsegment having the higher first density. The first 261 of the thickstaves is configured to provide the second material segment having thelower second density.

Floor-retaining flange 26 of floor mount 17 has an annular shape and isarranged to surround a vertically extending central axis CA interceptinga center point of horizontal platform 21 as suggested in FIGS. 3C and3D. The first 260 of the thin staves has an inner wall facing toward aportion of the vertically extending central axis CA passing through thelower interior region. Platform-support member 23 is arranged tosurround floor-retaining flange 26 and cooperate with horizontalplatform 21 to form a downwardly opening floor chamber 20C containingthe alternating series of upright thick and thin staves therein.

Each first material segment in the insulative cellular non-aromaticpolymeric material has a relatively thin first thickness. Each companionsecond material segment in the insulative cellular non-aromaticpolymeric material has a relatively thicker second thickness.

Body 11 is formed from a sheet 115 of insulative cellular non-aromaticpolymeric material that includes, for example, a strip of insulativecellular non-aromatic polymeric material 11S1 and a skin 11S2 coupled toone side of the strip of insulative cellular non-aromatic polymericmaterial 11S1 as shown in FIG. 12A. In one embodiment of the presentdisclosure, text and artwork or both can be printed on a film includedin skin 11S2. Skin 11S2 may further comprise an ink layer applied to thefilm to locate the ink layer between the film and the strip ofinsulative cellular non-aromatic polymeric material. In another example,the skin and the ink layer are laminated to the strip of insulativecellular non-aromatic polymeric material by an adhesive layer arrangedto lie between the ink layer and the insulative cellular non-aromaticpolymer material. As an example, the skin may be biaxially orientedpolypropylene.

Insulative cellular non-aromatic polymeric material comprises, forexample, a polypropylene base resin having a high melt strength, one orboth of a polypropylene copolymer and homopolymer resin, and one or morecell-forming agents. As an example, cell-forming agents may include aprimary nucleation agent, a secondary nucleation agent, and a blowingagent defined by gas means for expanding the resins and to reducedensity. In one example, the gas means comprises carbon dioxide. Inanother example, the base resin comprises broadly distributed molecularweight polypropylene characterized by a distribution that is unimodaland not bimodal.

An insulative cup 10 in accordance with one exemplary embodiment of thepresent disclosure includes a base 12 formed to include an interiorregion 14 and a rolled brim 16 coupled to base 12 as shown, for example,in FIG. 1. Base 12 includes a side wall 18, a support structure 19, anda floor 20 as shown in FIGS. 1, 2, 3C, and 9. Floor 20 is coupled tosupport structure 19 and side wall 18 to define interior region 14. Base12 illustratively comprises an insulative cellular non-aromaticpolymeric material that is configured (by application of pressure—withor without application of heat) to provide means for insulating abeverage or food placed in interior region 14, forming a structurehaving sufficient mechanical characteristics to support the beverage orfood, and providing resistance to deformation and puncture. As shown forexample in FIGS. 16-20, insulative cup 10 is formed in an illustrativecup-manufacturing process 40.

Side wall 18 extends between rolled brim 16 and support structure 19 asshown in FIG. 3. Side wall 18 includes a top portion 22 of base 12 thatis coupled to rolled brim 16 and a bottom portion 24 that is coupled tosupport structure 19. Support structure 19 is arranged to interconnectfloor 20 and bottom portion 24 of side wall 18. In the illustrativeembodiment, brim 16, side wall 18, and support structure 19 are formedfrom a unitary body blank 500 shown in FIG. 12. Insulative cup 10 is anassembly comprising the body blank 500 and the floor 20. As an example,floor 20 is mated with bottom portion 24 during cup-manufacturingprocess 40 to form a primary seal therebetween. A secondary seal mayalso be established between support structure 19 and floor 20. Aninsulative container may be formed with only the primary seal, only thesecondary seal, or both the primary and secondary seals.

Referring again to FIG. 1, top portion 22 of side wall 18 is arranged toextend in a downward direction 28 toward floor 20 and is coupled tobottom portion 24. Bottom portion 24 is arranged to extend in anopposite upward direction 30 toward rolled brim 16. Top portion 22 iscurled during cup-manufacturing process 40 to form rolled brim 16.Rolled brim 16 and top portion 22 cooperate to form a mouth 32 that isarranged to open into interior region 14.

Support structure 19 includes a floor-retaining flange 26 and aconnecting web 25 as shown in FIG. 3. Connecting web 25 is coupled tobottom portion 24 of side wall 18 and arranged to extend radially awayfrom bottom portion 24 toward interior region 14. Floor-retaining flange26 is coupled to connecting web 25 and is arranged to extend in upwarddirection 30 toward floor 20 and interior region 14. Together,floor-retaining flange 26, connecting web 25, and bottom portion 24cooperate to define receiving well 27 therebetween. As suggested in FIG.3, a portion of floor 20 is arranged to extend downwardly into receivingwell 27 and be retained between floor-retaining flange 26 and bottomportion 24. In the illustrative embodiment of FIG. 3, platform-supportmember 23 of floor 20 extends completely into receiving well 27 andcontacts connecting web 25.

In another embodiment shown in FIGS. 35 and 36, a cup 710 is similar toinsulative cup 10, but a floor 720 includes a floor platform 721 and afloor ring 723 that is shorter than platform-support member 23 ofinsulative cup 10. Floor ring 723 does not extend completely into areceiving well 727 formed between a retaining flange 726, connecting web725, and bottom portion 724. This approach allows floor 720 to bepositioned during the cup-manufacturing process 40 without need forclosely holding the dimensional length of floor ring 723 and reducingthe chance for interference during cup-manufacturing process 40.

As shown in FIGS. 1, 2, 3C, and 9, floor 20 includes horizontal platform21 and a platform-support member 23. Horizontal platform 21 is, forexample, a flat round disc which cooperates with side wall 18 to defineinterior region 14 therebetween. Platform-support member 23 is coupledto a perimeter of horizontal platform 21 and is arranged to extend indownward direction 28 away from horizontal platform 21 toward and intoreceiving well 27. As a result, horizontal platform 21 is spaced apartfrom any surface on which insulative cup 10 rests.

The compressibility of the insulative cellular non-aromatic polymericmaterial used in accordance with the present disclosure to produceinsulative cup 10 allows the insulative cellular non-aromatic polymericmaterial to be prepared for the mechanical assembly of insulative cup10, without limitations experienced by other polymeric materials. Thecellular nature of the insulative cellular non-aromatic polymericmaterial disclosed herein provides insulative characteristics asdiscussed below, while susceptibility to plastic deformation permitsyielding of the insulative cellular non-aromatic polymeric materialwithout fracture. The plastic deformation experienced when the strip ofinsulative cellular non-aromatic polymeric material is subjected to apressure load is used to form a permanent set in the insulative cellularnon-aromatic polymeric material after the pressure load has beenremoved. In some locations, the locations of permanent set arepositioned in illustrative embodiments to provide, for example,controlled gathering of the insulative cellular non-aromatic polymericmaterial.

Plastic deformation may also be used to create fold lines in theinsulative cellular non-aromatic polymeric material to controldeformation of the material when being worked during a cup assemblyprocess. When deformation is present the absence of material in thevoids formed by the deformation provides relief to allow the material tobe folded easily at the locations of deformation. Referring now to FIGS.4A and 5, an exemplary joint 600 between two portions 602 and 604 ofinsulative cellular non-aromatic polymeric material includes aninterface 606. Interface 606 includes contact between a surface 608 ofportion 602 and a surface 610 of portion 604, where the surfaces haveadhered to one another to create a seal and a mechanical interlockbetween portions 602 and 604. The interface includes a melt line 612where the non-aromatic polymeric material of each portion 602 and 604have commingled to secure to one another.

Portion 602 illustratively includes a structure of cells 614 that areenclosed by a non-aromatic polymeric material 624 with the cells 614closed to encapsulate a blowing agent comprising a gas such as CO₂, forexample. When pressure is applied at a location 616, localized areas618, 620, 622 of reduced cell size are created as the cells 614 arereduced in size and the non-aromatic polymeric material 624 flows toalter the shape of the cells 614. The flow of non-aromatic polymericmaterial 624 results in more non-aromatic polymeric material 624 beingcontained within a unit of volume than in undeformed areas such as areas626 and 628, for example. Thus, when a sufficient load is applied, thethickness of the insulative cellular non-aromatic polymeric material isreduced and the density in localized areas is increased.

In some instances, plastic deformation is achieved with a combination offorce and heat. Heating the insulative cellular non-aromatic polymericmaterial may reduce the force necessary to deform the material.Localized heating results in softening that permits plastic flow, atlower forces, to accomplish the desirable permanent set. This permitsdeformation of the cells to achieve a thinner, denser material inlocalized areas in the insulative cellular non-aromatic polymericmaterial.

In one illustrative embodiment, the present disclosure provides a strip652 of insulative cellular non-aromatic polymeric material havingpredominantly closed cells 614 dispersed in the insulative cellularnon-aromatic polymeric material 624 that exhibits unexpected, desirablephysical properties at a given material thickness. Such propertiesinclude, for example, insulative properties, strength/rigidityproperties, and puncture resistance properties. The illustrativematerial may be provided in a form such as, for example, an insulativecellular non-aromatic polymeric material sheet, strip, tube, thread,pellet, granule or other structure that is the result of extrusion of apolymer-based formulation, as herein described, through an extruder die.As described herein, an insulative cellular non-aromatic polymericmaterial may be mated with a biaxially oriented polypropylene film(i.e., film produced via a sequential biaxial stretching processinvolving two consecutive stretching steps conducted at two differenttemperatures) to establish a laminated sheet as well as a variety offinal products such as cups or insulative containers, wraps, wound rollsof material, and the like.

In one embodiment shown in FIG. 37, sheet 650 includes insulativecellular non-aromatic polymeric material 652 and a skin including a film658, an ink layer 656, and an adhesive layer 654. As an example, inklayer 656 may be printed on film 658 prior to adhering the skin toinsulative cellular non-aromatic polymeric material 652. In theillustrative embodiment of FIG. 37, film 658 comprises biaxiallyoriented polypropylene film.

In another embodiment shown in FIG. 38, a sheet 660 is similar to sheet650, but includes adhesive layer 654, ink layer 656, and film 658 onboth sides of a strip of insulative cellular non-aromatic polymericmaterial 652. In other embodiments, ink layer(s) 656 may be omitted onone or both sides.

In illustrative embodiments, an insulative cup is assembled fromcomponents that are formed from a material that is insulative. Theinsulative material includes a cellular non-aromatic polymeric structurethat is tough and rigid. The insulative cellular non-aromatic polymericmaterial is deformable plastically under pressure load such that thematerial takes a permanent set after the pressure load has been removedto create structural features facilitating formation of the insulativecup. In some embodiments, orderly gathering of the material when foldedor deformed is facilitated by the structure of the insulative cellularnon-aromatic material. In illustrative embodiments, the insulativecellular non-aromatic polymeric material is flexible to permit the cupto be used in sub-freezing temperatures without fracturing the material.As used herein, the term non-aromatic polymer refers to a polymer thatis devoid of aromatic ring structures (e.g., phenyl groups) in itspolymer chain.

Aromatic molecules typically display enhanced hydrophobicity whencompared to non-aromatic molecules. As a result, it would be expectedthat changing from a polystyrene-based insulative cellular polymericmaterial to a polypropylene-based insulative cellular polymeric materialwould result in a change in hydrophobicity with a concomitant, but notnecessarily predictable or desirable, change in surface adsorptionproperties of the resulting material. In addition, by virtue of thehydrocarbon chain in polystyrene, wherein alternating carbon centers areattached to phenyl groups, neighboring phenyl groups can engage inso-called pi-stacking, which is a mechanism contributing to the highintramolecular strength of polystyrene and other aromatic polymers. Nosimilar mechanism is available for non-aromatic polymers such aspolypropylene. Moreover, notwithstanding similar chemical reactivity andchemical resistance properties of polystyrene and polypropylene,polystyrene can be either thermosetting or thermoplastic whenmanufactured whereas polypropylene is exclusively thermoplastic. As aresult, to the extent that surface adsorption properties, manufacturingoptions, and strength properties similar to those of polystyrene aresought, likely alternatives to polystyrene-based insulative cellularpolymeric materials would be found in another aromatic polymer ratherthan in a non-aromatic polymer.

In illustrative embodiments, the insulative cellular non-aromaticpolymeric material is used as a substrate in a composite sheet thatincludes a film laminated to the insulative cellular non-aromaticpolymeric material. The film is reverse printed before being laminatedto the substrate so that the printing is visible through the film, withthe film forming a protective cover over the printing.

In illustrative embodiments, the insulative cellular non-aromaticpolymeric material may includes one or more polypropylene materials as abase material. The laminated film is also polypropylene so that theentire cup may be ground up and re-used in the same process.

Illustratively, in one exemplary embodiment, an insulative cellularnon-aromatic polymeric material may be polypropylene-based and may beformed from a composition comprising (a) a first material comprising atleast one high melt strength polypropylene resin; (b) a second materialcomprising at least one polypropylene resin selected from the groupconsisting of impact copolymers and high crystalline homopolymers; (c)at least one nucleating agent; (d) a blowing agent; and (e) a slipagent.

In one illustrative aspect, a polypropylene-based insulative cellularnon-aromatic polymeric material comprises a high melt strengthpolypropylene as a first material or base polymer resin. Melt strength,i.e., maximum drawdown force in a tensile experiment, is essentiallynon-existent for linear polypropylene. Melt strength is significantlyincreased, however, by the presence of long-chain branching. Theresulting high melt strength polypropylene, which contains long-chainbranches, provides a balance of processability and high melt elasticityrequired for foaming, thermoforming, and extrusion processes.

Suitable high melt strength polypropylenes have desirable gas retentionproperties, and impart desirable cell size and smooth surface finish toan insulative cellular non-aromatic polymer material, while also havingan acceptable odor, if any. One illustrative example of a suitable highmelt strength polypropylene resin is DAPLOY™ WB140 polypropylenehomopolymer (available from Borealis A/S):

Typical Property Value Unit Test Method Melt Strength 36 cN ISO 16790Melt Temperature 163 ° C. ISO 11357 Melt Flow Rate (230/2.16) 2.1 g/10min ISO 1133 Flexural Modulus 1900 MPa ISO 178 Tensile Strength at Yield40 MPa ISO 527-2 Elongation at Yield 6 % ISO 527-2 Tensile Modulus 2000MPa ISO 527-2 Charpy impact strength, 3.0 kJ/m² ISO 179/1eA notched(+23° C.) Charpy impact strength, 1.0 kJ/m² ISO 179/1eA notched (−20°C.) Heat Deflection Temperature A 60 ° C. ISO 75-2 Heat DeflectionTemperature B 110 ° C. ISO 75-2

In another illustrative aspect, a polypropylene-based insulativecellular non-aromatic polymeric material comprises a secondary polymerresin that is used in combination with the base polymer resin. Thesecondary polymer may be, for example, an impact polypropylenecopolymer, a high crystalline polypropylene homopolymer, or the like aswell as mixtures thereof. One illustrative example of an impactpolypropylene copolymer is a resin commercially available as PRO-FAXSC204™ (available from LyndellBasell Industries Holdings, B.V.).Exemplary homopolymers include, but are not limited to, Homo PP—INSPIRE222, available from Braskem, and high crystalline polypropylenehomopolymer, available as F020HC from Braskem. Several differentsecondary polymers may be used and mixed together.

In certain alternative exemplary embodiments, the secondary polymer maybe polyethylene, low density polyethylene, linear low densitypolyethylene, high density polyethylene, ethylene-vinyl acetatecopolymers, ethylene-ethylacrylate copolymers, ethylene-acrylic acidcopolymers, and like polymers. However, the use of non-polypropyleneresin materials may affect recyclability, insulation, microwavability,impact resistance, and/or other properties of the resulting insulativecellular non-aromatic polymeric material.

In another illustrative aspect, a polypropylene-based insulativecellular non-aromatic polymeric material comprises at least onenucleating agent. One or more nucleating agents are used to provide andcontrol nucleation sites to promote formation of bubbles, voids or cellsin the molten resin during an extrusion process. Suitable nucleatingagents will have desirable particle size, aspect ratio and top-cutproperties. Examples include, but are not limited to, talc, CaCO₃, micaand mixtures of at least two of the foregoing.

In another illustrative aspect, a polypropylene-based insulativecellular non-aromatic polymeric material comprises a blowing agent.Blowing agents introduce gas that expands cells in the resin mixture.Nucleating agents, in comparison, facilitate the formation of cells byproviding sites at which bubbles can form. As such, nucleating agentsand blowing agents work together to provide a cell-forming agent.Blowing agents act to reduce density by expanding cells in the moltenresin. Blowing agents may be physical or chemical agents. Physicalblowing agents are typically gases that are introduced into the moltenresin via a port in the extruder. Representative examples of gaseousblowing agents include, but are not limited to, carbon dioxide,nitrogen, pentane, butane or other alkanes, mixtures of gases and thelike. Alternatively, the gas may be a hydrofluorocarbon, such as1,1,1,2-tetrafluoroethane, also known as R134a, or other haloalkanerefrigerant. Selection of the blowing agent may be made to takeenvironmental impact into consideration.

Chemical blowing agents degrade or react at a particular temperature todecompose and produce a gas. Chemical blowing agents may be endothermicor exothermic. One illustrative example of an endothermic chemicalblowing agent is citric acid or a citric acid-based material. Onerepresentative example is Hydrocerol™ CF-40E™ (available from ClariantCorporation). Additional illustrative examples of chemical blowingagents include, but are not limited to, azodicarbonamide;azodiisobutyro-nitrile; benzenesulfonhydrazide; 4,4-oxybenzenesulfonylsemicarbazide; p-toluene sulfonyl semi-carbazide; bariumazodicarboxylate; N,N′-dimethyl-N,N′-dinitrosoterephthalamide;trihydrazino triazine; methane; ethane; propane; n-butane; isobutane;n-pentane; isopentane; neopentane; methyl fluoride; perfluoromethane;ethyl fluoride; 1,1-difluoroethane; 1,1,1-trifluoroethane;1,1,1,2-tetrafluoro-ethane; pentafluoroethane; perfluoroethane;2,2-difluoropropane; 1,1,1-trifluoropropane; perfluoropropane;perfluorobutane; perfluorocyclobutane; methyl chloride; methylenechloride; ethyl chloride; 1,1,1-trichloroethane;1,1-dichloro-1-fluoroethane; 1-chloro-1,1-difluoroethane;1,1-dichloro-2,2,2-trifluoroethane; 1-chloro-1,2,2,2-tetrafluoroethane;trichloromonofluoromethane; dichlorodifluoromethane;trichlorotrifluoroethane; dichlorotetrafluoroethane;chloroheptafluoropropane; dichlorohexafluoropropane; methanol; ethanol;n-propanol; isopropanol; carbon dioxide; nitrogen; argon; water; air;nitrogen; helium; sodium bicarbonate; sodium carbonate; ammoniumbicarbonate; ammonium carbonate; ammonium nitrite;N,N′-dimethyl-N,N′-dinitrosoterephthalamide;N,N′-dinitrosopentamethylene tetramine; azodicarbonamide;azobisisobutylonitrile; azocyclohexylnitrile; azodiaminobenzene;bariumazodicarboxylate; benzene sulfonyl hydrazide; toluene sulfonylhydrazide; p,p′-oxybis(benzene sulfonyl hydrazide); diphenylsulfone-3,3′-disulfonyl hydrazide; calcium azide; 4,4′-diphenyldisulfonyl azide; and p-toluene sulfonyl azide.

In another illustrative aspect, a polypropylene-based insulativecellular non-aromatic polymeric material comprises a slip agent. Slipagent is a term used to describe a general class of materials that areadded to a resin mixture to reduce or eliminate so-called die drool.Representative examples of slip agent materials include fats or fattyacids, such as erucamide and oleamide. Combinations of two or more slipagents can be used.

Illustratively, a polypropylene-based insulative cellular non-aromaticpolymeric material may be formed as an insulative cellular non-aromaticpolymeric material sheet by a process comprising (a) providing a firstmaterial comprising at least one high melt strength polypropylene resin;(b) providing a second material comprising at least one polypropyleneresin selected from the group consisting of impact copolymers and highcrystalline homopolymers; (c) mixing the first and second resins to forma resin mixture; (d) adding to the resin mixture at least one nucleatingagent; (e) adding to the resin mixture a slip agent; (f) adding to theresin mixture an inert gas as a blowing agent; (g) extruding the resinmixture to form an insulative cellular non-aromatic polymer materialmixture having cells therein; and (h) forming a strip of the insulativecellular non-aromatic polymer material mixture.

In one illustrative aspect, an exemplary polypropylene-based insulativecellular non-aromatic polymeric material formed as an insulativecellular non-aromatic polymeric material sheet may have a thicknessranging from about 60 mil to about 80 mil. In another illustrativeaspect, an exemplary polypropylene-based insulative cellularnon-aromatic polymeric material formed as an insulative cellularnon-aromatic polymeric material sheet may have a density ranging fromabout 0.15 g/cm³ to about 0.20 g/cm³. The insulative cellularnon-aromatic polymeric material is used in cup-manufacturing process 40to produce insulative cup 10 having a region of localized plasticdeformation. The region of localized plastic deformation may be theresult of compressing the insulative cellular non-aromatic polymericmaterial. The region of localized plastic deformation has a firstdensity in a range of about 0.3 g/cm³ to about 0.4 g/cm³. The insulativecellular non-aromatic polymeric material surrounding the region oflocalized plastic deformation is uncompressed and has a second densityin a range of about 0.15 g/cm³ to about 0.20 g/cm³.

As suggested in FIGS. 10 and 11, the density of the insulative cellularnon-aromatic polymeric material is indirectly proportional to the changein thickness of the material. As an example, if the material thicknessis reduced by half, then the density in the compressed area would aboutdouble.

In another illustrative aspect, an exemplary polypropylene-basedinsulative cellular non-aromatic polymeric material formed as a strip ofinsulative cellular non-aromatic polymeric material may have tensilestrength in the machine direction and cross direction ranging from about4.0 MPa to about 7.0 MPa and from about 3.0 MPa to about 6.0 MPa,respectively. In another illustrative aspect, an exemplarypolypropylene-based insulative cellular non-aromatic polymeric materialformed as a strip of insulative cellular non-aromatic polymeric materialmay have an elastic modulus in the machine direction and cross directionranging from about 160 MPa to about 240 MPa and from about 120 MPa toabout 170 MPa, respectively.

In another illustrative aspect, an exemplary insulative cellularnon-aromatic polymeric material formed as a strip of insulative cellularnon-aromatic polymer material may have cells in the shape of oriented,stretched ovals. In another illustrative aspect, an exemplarypolypropylene-based insulative cellular non-aromatic polymeric materialformed as a strip of insulative cellular non-aromatic polymeric materialmay average cell dimensions in machine direction 67 of about 0.0362inches (0.92 mm) in width by 0.0106 inches (0.27 mm) in height,resulting in a machine direction cell size aspect ratio of about 3.5.The average cell dimensions in cross direction or transverse to machinedirection 67 are about 0.0204 inches (0.52 mm) in width and about 0.0106inches (0.27 mm) in height, resulting in a cross direction cell sizeaspect ration of 1.94. As a result, the aspect ratio of foam cells isbetween about 1.0 and 3.0. In another example, the aspect ratio of foamcells is between about 1.0 and about 2.0.

Strip 82 of insulative cellular non-aromatic polymeric material is usedform insulative cup 10. Insulative cup 10 includes, for example body 11and floor 20 as shown in FIG. 1. Body 11 includes side wall 18 and floormount 17 which is coupled to floor 20 to support floor 20 in astationary position relative to sleeve-shaped side wall 18. Floor mount17 includes floor-retaining flange 26 coupled to floor 20, web-supportring 126 coupled to the lower end of sleeve-shaped side wall 18 andarranged to surround floor-retaining flange 26, and connecting web 25arranged to interconnect floor-retaining flange 26 and web-support ring126 as suggested in FIG. 3C.

As shown in FIG. 7, floor-retaining flange 26 includes an inner surface26A and an outer surface 26B. Inner surface 26A is arranged to facetoward platform-support member 23 and outer surface 26B is arranged toface opposite inner surface 26A. Floor-retaining flange 26 is furtherformed to include a series of spaced-apart depressions 518 formed inouter surface 26B. As an example, each depression 518 is linear having alongitudinal axis that overlies a ray emanating from a center 510 asshown in FIG. 12. In another example, depressions may be angular,diamond shaped, or one or more combinations thereof.

The resultant effect of the formation of depressions 518 on theinsulative cellular non-aromatic polymeric material is shown in FIGS.9B, 10, 11, and 14. Depressions 518 are formed in surface 26B and somecells 630 are reduced as the insulative cellular non-aromatic polymericmaterial is worked so that the insulative cellular non-aromaticpolymeric material takes a permanent set to form the depressions 518.The material 624 flows in the area of material flow such that cell walls632 of cells 630 are thinned while the skin 634 thickens in some areas.In the illustrative embodiment of FIGS. 10 and 11, the tool formingdepressions 518 has been heated so that there is some melting of thematerial 624 which causes the flow to thickened areas 634.

As shown in FIGS. 1, 2, and 3-3C, side wall 18 is formed to include aside wall seam 34 during an exemplary embodiment of cup-manufacturingprocess 40 illustrated in FIG. 16. Side wall 18 has a first wallthickness T1 which is present in both bottom portion 24 and retainingflange 26. Side wall 18 has a second wall thickness T2 which is presentat side wall seam 34. As shown in FIG. 6, thickness T2 is about equalthickness T1 as a result of compression of edges (inner and outer tabs)514, 512 (seen in FIG. 12) during cup-manufacturing process 40. As aresult, each tab 514, 512 has a third wall thickness T3 which is about50% of thicknesses T1, T2. Connecting web 25 also has an illustrativethird wall thickness T3 as a result of compression duringcup-manufacturing process 40. The connecting web 25 may have a differentthickness, other than thickness T3, in some embodiments. For example,the extent of the compression of connecting web 25 may be different thanthe extent of the compression of edges 512 and 514. Likewise, the extentof compression of one or the other of edges 512 and 514 may bedifferent, depending on application requirements.

In another exemplary embodiment, the side wall is not compressed aboutthe first and second edges. As a result, a thickness T2 may be greaterthan thickness T1. In one example where compression does not occur,thickness T2 may be about twice thickness T1.

In another exemplary embodiment, just one edge is compressed. Further,in another embodiment, a portion of one or both edges is compressed.

Side wall seam 34 continues up base 12 and into rolled brim 16 as shownin FIGS. 3 and 3B. As a result, rolled brim 16 has a first brimdimension B1 and a relatively equal second brim dimension B2 at the sidewall seam 34. The thickness of the material at the brim B3 is aboutequal to both first wall thickness T1 and second wall thickness T2. Asshown in FIG. 6, brim dimension B2 is about equal to brim dimension B1as a result of compression of first and second edges 512, 514 duringcup-manufacturing process 40. As a result, each edge 512, 514 in rolledbrim 16 has a third brim thickness B3 which is about 50% of thicknessesB1, B2.

The compression of first and second edges 512, 514 permits brimdimension B2 to match brim dimension B1, regardless of the brimgeometry. As will be discussed in further detail below, the shape of thebrim may vary from the geometry of brim 16 in other embodiments. Brim 16is configured to serve as both a drinking brim and a sealing brim. Asseen in FIG. 6, an inner surface 108 of side wall 18 tangentiallyintersects an outer diameter 110 of brim 16 at a point 112 while anouter surface 106 terminates at brim 16. Transition point 112 provides asmooth transition for a flow of liquid if a user were to drink frominsulative cup 10, without spilling or disrupting flow over brim 16.Referring now to FIGS. 6A and 6B, brim 16 also serves to cooperate witha retainer 114 of a lid 116 to secure lid 116 to insulative cup 10 witha liquid seal so that a user may use a drinking spout 118 of lid 116without having liquid escape between lid 116 and brim 16. Retainer 114snaps over and engages diameter 110 of brim 16 so that a flange 122 oflid 116 engages diameter 110 at a point 120 to seal lid 116 toinsulative cup 10.

Alternative embodiments of a rolled brim are disclosed in FIGS. 32-34and each embodiment may be substituted for rolled brim 16. For example,rolled brim 16A shown in FIG. 32 has a constant thickness of insulativecellular non-aromatic polymeric material with dimensions X₁, X₂, and X₃being generally equal, but with a brim thickness B4 that is greater thanthe brim thickness B1 of insulative cup 10. A larger brim thickness B4provides clearance in the interior space 900 of brim 16A, improving themanufacturability of brim 16A by allowing clearance during brim rolling.

A rolled brim 16B has wall thickness X₁ that is reduced and thinnedduring the brim rolling process that results in a reduction at X₂ and afurther reduction at X₃ as shown in FIG. 33. Brim 16B is relativelyeasier to manufacture than brim 16A and provides a brim with a brimthickness B5 that is approximately the same as brim thickness B4, buthas a brim height B6 that is larger than B5. This results in additionalrelief in an interior space 904 of brim 16B. Brim 16B is more suitablefor use with lids by providing additional contact area for sealing.

In still another embodiment, rolled brim 16C approximates a solid brimwith a first wall dimension X₁ that is reduced to X₂, further reduced atX₃, and rolled about itself at X₄ and X₅ as shown in FIG. 34. Withheating and or compression, brim 16C provides a solid brim structurewith a high rigidity due to the lack of relief in an interior space ofbrim 16C. Such a brim is suitable for drinking and provides a rigiditythat assists with maintaining a snap fit lid, such as lid 116 in placeduring use. In the embodiment of FIG. 34, the brim thickness B7 isapproximately equal to brim thickness B1 in insulative cup 10.

Side wall 18 is formed during cup-manufacturing process 40 using a bodyblank 500 as suggested in FIGS. 16-20. Body blank 500 may be producedfrom a strip of insulative cellular non-aromatic polymeric material, alaminated sheet 80 as shown in FIG. 16 and discussed in further detailbelow, or a strip of insulative cellular non-aromatic polymeric materialthat has been printed on. Referring now to FIGS. 12 and 13, body blank500 is generally planar with a first side 502 and a second side 504(seen in FIG. 12). Body blank 500 is embodied as a circular ring sectorwith an outer arc length S₁ that defines a first edge 506 and an innerarc length S₂ that defines a second edge 508. The arc length S₁ isdefined by a subtended angle Θ in radians times the radius R₁ from anaxis 510 to the edge 506. Similarly, inner arc length S₂ has a lengthdefined as subtended angle Θ in radians times the radius R₂. Thedifference of R₁-R₂ is a length h which is the length of two linearedges 512 and 514. Changes in R₁, R₂ and Θ can will result in changes inthe size of insulative cup 10. First linear edge 512 and second linearedge 514 each lie on a respective ray emanating from center 510. Thus,body blank 500 has two planar sides, 502 and 504, as well as four edges506, 508, 512, and 514 which define the boundaries of body blank 500.The edges 512 and 514 may correspond to and have treatments as describedbelow.

Fold line 516 has a radius R₃ measured between center 510 and a foldline 516 and fold line 516 has a length S3. As shown in FIG. 12, R₁ isrelatively greater than R₃. R₃ is relatively greater than R₂. Thedifferences between R₁, R₂, and R₃ may vary depending on theapplication.

Fold line 516 shown in FIG. 12 is a selected region of a strip ofinsulative cellular non-aromatic polymeric material that has beenplastically deformed in accordance with the present disclosure (byapplication of pressure—with or without application of heat) to induce apermanent set resulting in a localized area of increased density andreduced thickness. The thickness of the insulative cellular non-aromaticpolymeric material at fold line 516 is reduced by about 50% as shown inFIG. 12. In addition, the blank is formed to include a number ofdepressions 518 or ribs 518 positioned between the arcuate edge 508 andfold line 516 with the depressions 518 creating a discontinuity in asurface 531. Each depression 518 is linear having a longitudinal axisthat overlies a ray emanating from center 510. As discussed above,depressions 518 promote orderly forming of floor-retaining flange 26.The insulative cellular non-aromatic polymer material of reducedthickness at fold line 516 ultimately serves as connecting web 25 in theillustrative insulative cup 10. As noted above, connecting web 25promotes folding of floor-retaining flange 26 inwardly toward interiorregion 14. Due to the nature of the insulative cellular non-aromaticpolymeric material used to produce illustrative body blank 500, thereduction of thickness in the material at fold line 516 and depressions518 owing to the application of pressure—with or without application ofheat—increases the density of the insulative cellular non-aromaticpolymeric material at the localized reduction in thickness.

As shown in FIG. 13, each depression 518 is spaced apart from eachneighboring depression a first distance 551. In an illustrative example,first distance 551 is about 0.067 inches (1.7018 mm). Each depression518 is also configured to have a first width 552. In an illustrativeexample, first width 552 is about 0.028 inches (0.7112 mm). Eachdepression 518 is also spaced apart from fold line 516 a second distance553. In an illustrative example, second distance 553 is about 0.035inches (0.889 mm).

Depressions 518 and fold line 516 are formed by a die that cuts bodyblank 500 from a strip of insulative cellular non-aromatic polymericmaterial, laminated sheet 80, or a strip of printed-insulative cellularnon-aromatic polymeric material and is formed to include punches orprotrusions that reduce the thickness of the body blank 500 inparticular locations during the cutting process. The cutting andreduction steps could be performed separately as suggested in FIG. 17,performed simultaneously, or that multiple steps may be used to form thematerial. For example, in a progressive process, a first punch orprotrusion could be used to reduce the thickness a first amount byapplying a first pressure load. A second punch or protrusion could thenbe applied with a second pressure load greater than the first. In thealternative, the first punch or protrusion could be applied at thesecond pressure load. Any number of punches or protrusions may beapplied at varying pressure loads, depending on the application.

As shown in FIGS. 7-11, depressions 518 permit controlled gathering offloor-retaining flange 26 supporting a platform-support member 23 andhorizontal platform 21. Floor-retaining flange 26 bends about fold line516 to form receiving well 27 with fold line 516 forming connecting web25. The absence of material in depressions 518 provides relief for theinsulative cellular non-aromatic polymeric material as it is formed intofloor-retaining flange 26. This controlled gathering can be contrastedto the bunching of material that occurs when materials that have norelief are formed into a structure having a narrower dimension. Forexample, in traditional paper cups, a retaining flange type will have adiscontinuous surface due to uncontrolled gathering. Such a surface isusually worked in a secondary operation to provide an acceptable visualsurface, or the uncontrolled gathering is left without furtherprocessing, with an inferior appearance. The approach of forming thedepressions 518 in accordance with the present disclosure is anadvantage of the insulative cellular non-aromatic polymeric material ofthe present disclosure in that the insulative cellular non-aromaticpolymeric material is susceptible to plastic deformation in localizedzones in response to application of pressure (with or withoutapplication of heat) to achieve a superior visual appearance.

Referring again to the embodiment of FIGS. 35 and 36, cup 710 is similarto insulative cup 10, but cup 710 is formed with depressions 718 formedon a surface 726A which corresponds to the surface 26A of insulative cup10. Depressions 718 being formed on surface 726A leaves a smooth,un-interrupted surface 726B. Referring now to FIGS. 7A and 8, theinteraction of retaining flange 726 and bottom portion 724 with floorring 723 is shown as photographed to show the thickening and thinning ofnon-aromatic polymer material 624 and distortion of cells 614 as the cup710 is assembled.

As one illustrative example of a method of manufacturing, insulative cup10 is made in accordance with cup-manufacturing process 40 as shown inFIGS. 16-20. As shown in FIGS. 16 and 17, laminated sheet 80 is acomposite formed of a strip of insulative cellular non-aromaticpolymeric material 82 onto which a skin 84 is laminated from a roll 78at a laminating stage 44. Roll 86 of laminated sheet 80 is fed to thecup-forming stage 45. Cup-forming stage 45 illustratively includes abody blank forming step 451, an optional body blank annealing step 451a, a cup-base forming step 452, and a brim-forming step 453 as shown inFIG. 16. Body blank forming step 451 uses laminated sheet 80 to make abody blank 92 as shown in FIG. 17. Cup-base forming step 452 uses sidewall blanks 92 along with another laminated sheet 80 provided by anotherlaminated roll 86 to form a floor blank 90, form side wall 18, and joinside wall 18 to floor 20 to establish base 12 as shown in FIG. 18.Brim-forming step 453 rolls top portion 22 of base 12 to form rolledbrim 16 on base 12 as suggested in FIG. 19.

An unexpected property of laminated sheet 80 including a strip ofinsulative cellular non-aromatic polymeric material 82 is its ability toform noticeably smooth, crease and wrinkle free surfaces when bent toform a round article, such as insulative cup 10. Surface 106 is smoothand wrinkle free as is surface 108. The smoothness of the surfaces 106and 108 of the present disclosure is such that the depth of creases orwrinkles naturally occurring when subjected to extension and compressionforces during cup-manufacturing process 40 is less than 100 micron andeven less than 5 micron in most instances. At less than 10 micron, thecreases or wrinkles are not visible to the naked eye.

It has been found during development of the present disclosure that ifthe circumference of insulative cup 10 is aligned with the machinedirection 67 of extruded insulative cellular non-aromatic polymericmaterial 82, deep creases with a depth in excess of 200 micron aretypically formed on surface 108. Unexpectedly, it has been determinedthat if the circumference of insulative cup 10 is aligned generallyperpendicular to machine direction 67 as shown in FIG. 16, no deepcreases are formed on surface 108, indicating that the cross-direction66 to machine direction 67 of extruded insulative cellular non-aromaticpolymeric material 82 is resistant to compression forces duringformation of insulative cup 10. It is believed that this is a result ofthe orientation of the polymer chains of extruded insulative cellularnon-aromatic polymeric material 82 which are oriented and more tightlypacked in machine direction 67.

Body blank forming step 451 includes a laminated-roll loading step 4511,an optional annealing step 4511 a, a compressing step 4512, a cuttingstep 4513, a collecting scrap step 4514, and an accumulating blanks step4515 as shown in FIG. 17. Laminated-roll loading step 4511 loadslaminated roll 76 onto a cutting machine such as a die cutting machineor metal-on-metal stamping machine. As a result, laminated sheet 80 isdrawn into the cutting machine for processing. The optional annealingstep 4511 a heats laminated sheet 80 as it moves to the cutting machineso that stresses in the non-aromatic polymer structure of laminatedsheet 80 are released to reduce creasing and wrinkling in surfaces 106and 108 of insulative cup 10. Compressing step 4512 compresses portionsof laminated sheet 80 to form a compressed sheet. As an example,compressing step 4512 forms fold line 516 and depressions 518 as shownin FIG. 12. Cutting step 4513 cuts compressed sheet to cause body blank92 to be cut from a blank-carrier sheet 94. Collecting scrap step 4514collects blank-carrier sheet 94 after cutting step 4513 is complete sothat blank-carrier sheet 94 may be recycled. Accumulating blanks step4515 accumulates each body blank 92 to form a body blank stack 95 foruse in cup-base forming step 452 as shown in FIG. 19.

Cup-base forming step 452 includes a body blanks loading step 4521A, aheating body blank step 4522A, a wrapping body blank step 4523A, aforming side wall step 4524A, a laminated-roll loading step 4521B, acutting floor blanks step 4522B, a shaping floor step 4523B, a heatingfloor step 4524B, a heating body step 4525A, a wrapping body step 4526,and a floor-seam forming step 4527 as shown in FIG. 18. Body blanksloading step 4521A loads body blank stack 95 into a cup-forming machinefor further processing. Heating body blank step 4522A applies heat 96 tobody blank 92. Wrapping body blank step 4523A wraps heated body blank 92around a mandrel included in the cup-forming machine. Forming side wallstep 4524A forms side wall 18 by compressing portions of side wall 18using primary and auxiliary seam clamps included in the cup-formingmachine. Primary and auxiliary seam clamps provide localize compressionwhich results a portion of side wall 18 having thickness T2 and anotherportion having thickness T1 as shown in FIG. 4. An example, thickness T2is about equal to thickness T1.

Laminated-roll loading step 4521B loads another laminated roll 76 ontothe cup-forming machine to cause laminated sheet 80 to be drawn intocup-forming machine for processing. Cutting floor blanks step 4522B cutslaminated sheet 80 to cause floor blank 90 to be cut from ablank-carrier sheet 94. Blank-carrier sheet 94 may then be collected andrecycled. Shaping floor step 4523B forms floor 20 by inserting floorblank 90 into the mandrel of the cup-forming machine. Heating floor step4524B applies heat 96 to floor 20 at the same time heating body step4525A applies heat 96 to side wall 18. Wrapping body 4526 wraps supportstructure 19 around platform-support member 23 of floor 20. Floor-seamforming step 4527 compresses floor 20 and side wall 18 to establish afloor seam or seal between floor 20 and side wall 18 to establish base12 which is then ready for brim-forming step 453 as shown in FIG. 19.

The cup-base forming step 452 advantageously maintains the thickness T1of the side wall 18 as compared to a thermoforming process. Rather thanheating an insulative cellular non-aromatic polymeric material andworking it over a mandrel in the thermoforming process, subjectingportions of the wall of the resulting cup to thinning and potentiallyreducing the insulative and structural properties thereof, cup-baseforming step 452 is an assembly process that does not require the entireside wall 18 to be subjected to melting temperatures. This provides theadvantage of maintaining consistency in thickness T1 of side wall 18and, thereby, consistent and superior insulating properties as comparedto vessels subjected to a deep draw thermoforming process.

Brim-forming step 453 includes a transferring cup-base step 4531, anoptional lubricating top-portion step 4532, heating top-portion step4533, and rolling top-portion step 4534 as shown in FIG. 19.Transferring cup-base step 4531 transfers base 12 from a cup-baseforming machine to a brim-forming machine. Lubricating top-portion step4532 lubricates top portion 22 of base 12. Heating top-portion step 4533applies heat 96 to top portion 22 of base 12. Curling top-portion step4534 curls top portion 22 away from interior region 14 to establishrolled brim 16 and form insulative cup 10.

Cup-packaging stage 46 includes a leak inspecting step 461, anaccumulating cups step 462, and a packaging cups step 463 as shown inFIG. 20. Leak inspecting step 461 inspects each insulative cup 10 formedduring brim-forming step 453 for leaks. Those cups failing the leakinspection are collected and recycled owing to formation of those cupsfrom insulative cellular non-aromatic polymeric material. Those cupspassing the leak inspection are accumulated in accumulating cups step462 to form a stack 98 of insulative cups. Packaging cups step 463stores stack 98 of insulative cups for storage, use, or transportationas shown in FIG. 20.

While the ability of insulative cellular non-aromatic polymeric materialof the present disclosure to be subjected to plastic deformation underexposure to pressure loads (with or without application of heat) suchthat the material takes a permanent set has been discussed above,another embodiment of a body blank 800 is shown in FIGS. 21 and 22. Thebody blank 800 takes advantage of the properties of the disclosedinsulative cellular non-aromatic polymeric material when two reducedareas 802 and 804 are formed in body blank 800 to provide relief for theoverlap of material when a brim, such as brim 16 is rolled on a cup.Body blank 800 is similar to body blank 500, with the addition of thereduced areas 802 and 804. As shown in FIG. 21, areas 802 and 804 arereduced in thickness by about 50% so that when a cup is formed from bodyblank 800, the thickness of the brim where areas 802 and 804 overlap isapproximately the same as in areas where there is no overlap.

In another embodiment, a body blank 820 includes reduced areas 822 and824 along the linear sides 826 and 828 of the body blank 820 as shown inFIGS. 23 and 24. Reduced areas 822 and 824 are reduced in thickness byabout 50% so that when reduced areas 822 and 824 are overlapped duringcup-manufacturing process 40, the thickness at the overlapping seam isapproximately the same as the remainder of the side wall of the cupformed from wall blank 820.

In yet another embodiment, a cup 830 includes a side wall 832 which isformed to include a number of ribs 834 extending from a reduced area 838of side wall 832 as shown in FIGS. 25-27. A body blank 836 is reduced inareas 838, 840, 842, and 844 so that ribs 834 extend away from thereduced areas 838, 840, 842, and 844. Ribs 834 provide an air gap orspacing between a hand of user holding cup 830 and the remainder of theside wall 832, to reduce the contact area. Ribs 834 may also becontacted by a sleeve (not shown) placed on cup 830 to provide air gapsbetween the reduced areas 838, 840, 842, and 844 and the sleeve toinsulate a user's hand.

In still yet another embodiment, a cup 850 shown in FIG. 28 includesribs 852 formed in a side wall 854 through displacement of portions of awall blank 856, shown in FIG. 29, as suggested by FIGS. 30 and 31. Inearlier embodiments, insulative cellular non-aromatic polymeric materialwas plastically deformed to create permanent set to reduce a thickness.In the illustrative cup 850, material is displaced by permitting reliefwhen the strip of insulative cellular non-aromatic polymeric material isacted upon by pressure loads so that the material moves as suggested byFIGS. 30 and 31, the strip of insulative cellular non-aromatic polymericmaterial deforms to create depressions 864 on one side and protrudingribs 852 on the opposite side. The strip of insulative cellularnon-aromatic polymeric material deforms such that some thinning occursin an area 858, while the thickness of the displaced wall 860 remainsapproximately equal to the thickness 862 of the side wall 854.Protrusions 852 serve a similar purpose as ribs 834 discussed above withregard to cup 830. The advantage of protrusions 852 is that thethickness of side wall 854 remains generally constant while continuingto provide the insulative properties of a full thickness wall and theadvantages of ribs.

The embodiments discussed herein may be formed of mw insulative cellularnon-aromatic polymeric material or any variation of composites using theinsulative cellular non-aromatic polymer material as disclosed herein.This includes embodiments that laminate one or both sides with apolymeric film.

In another exemplary embodiment of a cup-forming process, thecup-manufacturing process 40 described hereinabove is modified by notlaminating the film layer to the substrate. As a result, the film layeris entirely omitted and printing may done directly on the insulativecellular non-aromatic polymeric material layer.

The material of the present disclosure may also be formed into adeformable sheet which can be wrapped around other structures. Forexample, a sheet of the present material may be formed and wrappedaround a pipe, conduit or other structure to provide improvedinsulation.

A potential feature of an insulative cup formed of insulative cellularnon-aromatic polymeric material according to exemplary embodiments ofthe present disclosure is that the cup has low material loss.Furthermore, the material of the present disclosure may have markedlylow off-gassing when subjected to heat from a conventional kitchen-typemicrowave oven for periods of time up to several minutes.

Another potential feature of an insulative cup formed of insulativecellular non-aromatic polymeric material according to the presentdisclosure is that the cup can be placed in and go through aconventional residential or commercial dishwasher cleaning cycle (toprack) without noticeable structural or material breakdown or adverseaffect on material properties. This is in comparison to beaded expandedpolystyrene cups or containers which can break down under similarcleaning processes. Accordingly, a cup made according to one aspect ofthe present disclosure can be cleaned and reused.

Another potential feature of an insulative cup formed of insulativecellular non-aromatic polymeric material according to various aspects ofthe present disclosure is that the insulative cup and scrap material canbe recycled. Recyclable means that a material can be added (such asregrind) back into an extrusion or other formation process withoutsegregation of components of the material. As an example, an insulativecup formed the insulative cellular non-aromatic polymeric material doesnot have to be manipulated to remove one or more materials or componentsprior to re-entering the extrusion process.

In another example, an insulative cup formed from a sheet including aprinted film skin laminated to an exterior of an insulative cellularnon-aromatic polymeric material may be recyclable if one does not needto separate out the film layer prior to the insulative cup being groundinto particles. In contrast, a paper-wrapped expanded polystyrene cupmay not be recyclable because the polystyrene material could notpracticably be used as material in forming an expanded polystyrene cup,even though the cup material may possibly formed into another product.

As a further example, an insulative cup formed from a non-expandedpolystyrene material having a layer of printed film adhered thereto maybe considered non-recyclable because it would require the segregation ofthe film layer, which would not be desirable to introduce as part of theregrind into the extrusion process. Recyclability of articles formedusing the insulative cellular non-aromatic polymeric material of thepresent disclosure minimize the amount of disposable waste created. Incomparison, beaded expanded polystyrene cups that break up into beadsand thus ordinarily cannot be reused easily in a manufacturing processwith the same material from which the article was formed. In addition,paper cups that typically have an extrusion coated plastic layer or aplastic lamination for liquid resistance ordinarily cannot be recycledbecause the different materials (paper, adhesive, film, plastic)normally cannot be practicably separated in commercial recyclingoperations.

A potential feature of an insulative cup formed of insulative cellularnon-aromatic polymeric material according to one aspect (a non-laminateprocess) of the present disclosure is that the outside (or inside orboth) wall surface of the insulative cellular polypropylene sheet (priorto being formed into an insulative cup, or during cup formation,depending on the manufacturing process employed) can accept printing ofhigh-resolution graphics. In contrast, beaded expanded polystyrene cupshave a surface which typically is not smooth enough to accept printingother than low-resolution graphics. Like beaded expanded polystyrenecups, uncoated paper cups also typically do not have a smooth enoughsurface for such high-resolution graphics. Paper cups have difficultyreaching insulation levels and require a designed air gap incorporatedinto or associated with the paper cup to achieve insulation. Suchdesigned air gap may provided by a sleeve slid onto and over a portionof the paper cup.

A potential feature of an insulative cup formed of insulative cellularnon-aromatic polymeric material according to one aspect of the presentdisclosure is that it possesses unexpected strength as measured byrigidity. Rigidity is a measurement done at room temperature and at anelevated temperature (e.g., by filling the cup with a hot liquid) andmeasuring the rigidity of the material. The strength of the cup materialis important to minimize deformation of the cup as the cup is beinghandled by a user.

A potential feature of an insulative cup formed of insulative cellularnon-aromatic polymeric material according to the present disclosure isthat insulative cup is resistant to puncture, such as by a straw, fork,spoon, finger nail, or the like, as measured by standard impact testing,as described hereinbelow. Test materials demonstrated substantiallyhigher impact resistance when compared to a beaded expanded polystyrenecup. As a result, an insulative cup in accordance with the presentdisclosure may minimize the likelihood of puncture and leakage of hotliquid.

Insulative cup 10 of the present disclosure satisfies a long-felt needfor a vessel that includes many if not all the features of insulativeperformance, ready for recyclability, high-quality graphics, chemicalresistance, puncture resistance, frangibility resistance, stainresistance, microwavability, and resistance to leaching undesirablesubstances into products stored in the interior region of the drink cupas discussed above. Others have failed to provide a vessel that achievescombinations of these features as reflected in the appended claims. Thisfailure is a result of the many features being associated withcompetitive design choices. As an example, others have created vesselsthat based on design choices are insulated but suffer from poor punctureresistance, lack of microwavability, and leech undesirable substancesinto products stored in the interior region. In comparison, insulativecup 10 overcomes the failures of others by using an insulative cellularnon-aromatic polymeric material.

EXAMPLES

The following examples are set forth for purposes of illustration only.Parts and percentages appearing in such examples are by weight unlessotherwise stipulated. All ASTM, ISO, and other standard test methodcitations referenced and other testing methodologies referred to in thisdisclosure are incorporated by reference in their entirety.

Example 1—Formulation and Extrusion

DAPLOY™ WB140 polypropylene homopolymer (available from Borealis A/S)was used as the polypropylene base resin. F020HC, available fromBraskem, a polypropylene homopolymer resin, was used as the secondaryresin. The two resins were blended with: Hydrocerol™ CF-40E™ as aprimary nucleation agent, talc as a secondary nucleation agent, CO₂ as ablowing agent, a slip agent, and titanium dioxide as a colorant.Percentages were:

-   -   79.9% Primary resin: high melt strength polypropylene Borealis        WB140 HMS15%    -   Secondary resin: F020HC (Braskem)    -   0.1% Primary nucleating agent: Clariant Hyrocerol CF-40E™ 2%        Secondary    -   nucleating agent: Talc    -   1% Colorant: TiO₂ PE (alternatively, PP can be used)    -   2% Slip agent: Ampacet™ 102823 LLDPE (linear low-density        polyethylene), available from Ampacet Corporation

The formulation was added to an extruder hopper. The extruder heated theformulation to form a molten resin mixture. To this mixture was added:

-   -   1.1 lbs/hr CO₂    -   0.7 lbs/hr R134a

The carbon dioxide with R134a was injected into the resin blend toexpand the resin and reduce density. The mixture thus formed wasextruded through a die head into a sheet. The sheet was then cut andformed into a cup.

Example 1—Test Results

The test results of the material formed according to Example 1 showedthe material had a density of 0.1902 g/cc and a nominal sheet gauge of0.089 inches.

Microwavability

Containers produced using this material filled with 12 ounces of roomtemperature water were heated in a FISO Microwave Station (1200 Watts)microwave oven for 2.5 min without burning or scorching or other visibleeffect on the cup. In comparison, paper cups heated in the samemicrowave oven scorched or burned in less than 90 seconds.

Rigidity

Test Method

Samples were at 73° F. and 50% relative humidity. The CupStiffness/Rigidity test was conducted with a horizontal force gaugecontaining a load cell to measure the resisting force of the cup whenexposed to the following test conditions: (a) The test location on thecup was ⅓ down from the rim of the cup. (b) Testing travel distance is ¼inches. (c) Testing travel time was 10 seconds.

Test Results

With an average wall thickness of 0.064 inches, average density of0.1776 g/cc, and average cup weight of 9.86 g, the rigidity of thematerial are shown below in Tables 1-2.

TABLE 1 Rigidity Test Results Rigidities (kg-F) Cup # Seam 90° from SeamAverage unlidded/unfilled 1 0.64 0.654 0.647 2 0.646 0.672 0.659 3 0.6320.642 0.637 4 0.562 0.608 0.585 5 0.652 0.596 0.624 0.630 STD DEV 0.0283sigma 0.085 High Range 0.716 Low Range 0.545 lidded/unfilled 6 0.890.83  0.860 7 0.954 0.904 0.929 8 0.846 0.808 0.827 9 0.732 0.826 0.77910 0.87 0.792 0.831 0.845 STD DEV 0.055 3sigma 0.165 High Range 1.011Low Range 0.680 unlidded/filled 200° F. 11 0.274 0.290 0.282 12 0.2780.326 0.302 13 0.264 0.274 0.269 14 0.300 0.270 0.285 15 0.252 0.2800.266 0.281 STD DEV 0.014 3sigma 0.043 High Range 0.324 Low Range 0.238lidded/filled 200° F. 16 0.346 0.354 0.350 17 0.386 0.422 0.404 18 0.3580.364 0.361 19 0.338 0.374 0.356 20 0.304 0.272 0.288 0.352 STD DEV0.042 3sigma 0.125 High Range 0.476 Low Range 0.227 unlidded/filled icewater 21 0.796 0.730 0.763 22 0.818 0.826 0.822 23 0.894 0.760 0.827 240.776 0.844 0.810 25 0.804 0.714 0.759 0.796 STD DEV 0.033 3sigma 0.098High Range 0.894 Low Range 0.698 lidded/filled ice water 26 1.044 0.8920.968 27 1.146 1.018 1.082 28 0.988 1.054 1.021 29 1.012 1.106 1.059 300.826 1.058 0.942 1.014 STD DEV 0.059 3sigma 0.177 High Range 1.192 LowRange 0.837

TABLE 2 Summary of Rigidity Test Results Unfilled Kg-F Ice Water Fill35° F. Wall (kilograms-force) Hot Fill 200° F. Kg-F Kg-F ThicknessDensity Unlidded Lidded Unlidded Lidded Unlidded Lidded Inches g/cc Testmaterial 0.630 0.845 0.281 0.352 0.796 1.014 0.064 0.1776Insulation

Test Method

A typical industrial cup insulation test method as follows was used: s

-   -   Attach the (cup exterior) surface temperature thermocouple to        cup with glue.    -   Tape attached thermocouple to cup with cellophane tape so that        the thermocouple is in the middle of the cup opposite the seam.    -   Heat water or other aqueous liquid to near boiling, such as in a        microwave.    -   Continually stir the hot liquid with a bulb thermometer while        observing the liquid temperature.    -   Record thermocouple temperature.    -   When the liquid gets to 200° F. pour into cup to near full.    -   Place lid on cup.    -   Record surface temperature for a minimum of 5 minutes.

A cup formed from the formulation noted above was used having a densityof 0.1902 g/cm³ and a wall thickness of 0.089 inches (2.2606 mm). A hotliquid at 200° F. (93.3° C.) was placed in the cup.

Test Results

The temperature measured on the outside wall of the cup was about 140.5°F. (60.3° C.), i.e., a 59.5° F. (33° C.) drop. The maximum temperatureover a five-minute period was observed to peak at 140.5° F. (60.3° C.).

The lower the temperature, the better the insulation property of the cupmaterial as the material reduces the heat transferring from the liquidto the cup material exterior.

Frangibility

Frangibility can be defined as resistance to tear or punctures causingfragmentation.

Test Method

The Elmendorf test method described in ASTM D1922-93 was used. Theradius of tear was 1.7 inches.

Test Results

The test results are shown in Tables 3-4 below. The material as formedin one exemplary embodiment of the present disclosure provides superiorresistance to tear forces when compared to EPS.

TABLE 3 Test Results Machine Direction (gram force) Transverse Direction(gram force) Tag Test 1 Test 2 Test 3 Test 4 Test 5 mean std dev. Test 1Test 2 Test 3 Test 4 Test 5 mean std dev. Test 288 262 288 258 315 28223 232 213 178 205 232 212 23 Material EPS 108 114 112 116 110 112 3 *

TABLE 4 Summary of Test Results Sample ID Test Expanded material cuppolystyrene Elmendorf Tear machine g (gram) 800 800 direction (MD) ArmElmendorf Tear MD gf (gram 282 112 force) Elmendorf Tear transverse g800 n/a direction (TD) Arm Elmendorf Tear TD gf 212 n/a

Note that there was no data obtained for the transverse direction testfor EPS because EPS does not have a material orientation, i.e., amachine or transverse direction, as such. The range (calculated as:lower range=mean−(3×std dev); upper range=mean+(3×std dev)) for thetested material of the present disclosure was 213-351 g-f in the machinedirection and 143-281 g-f in the transverse direction. In comparison,the range of the expanded polystyrene material tested was 103-121 g-f.

Puncture Resistance

Test Method

Determine the force and travel needed to puncture cup sidewall andbottom. An Instron instrument is used in compression mode set to 10inches per minute travel speed. The cup puncture test fixture on base ofInstron is used. This fixture allows the cup to fit over a shape thatfits inside the cup with a top surface that is perpendicular to thetravel of the Instron tester. The one inch diameter hole of the fixtureshould be positioned up. The portion of the Instron that moves should befitted with a 0.300 inch (7.62 mm) diameter punch. The punch with thehole is aligned in the test fixture. The cup is placed over the fixtureand the force and travel needed to puncture the cup sidewall isrecorded. The sidewall puncture test is repeated in three evenly spacedlocations while not puncture testing on the seam of the cup. The bottomof the cup is tested. This should be done in the same manner as thesidewall test except no fixture is used. The cup is just placed upsidedown on the base of the Instron while bringing the punch down on thecenter of the cup bottom.

Test Results

Force curves and pictures of the typical sidewall puncture and thebottom puncture are shown in Table 5 below.

TABLE 5 Puncture Test Results Cavity # Max Load (lbf) Ext. @ Max Load(in) Expanded polystyrene 3.79 0.300 TROPHY ® 6.61 0.155 testedinsulative cellular 22.18 0.292 non-aromoatic polymeric material (NoRim)Slow Puncture—Straw

Test Method

The material as formed in one exemplary embodiment of the presentdisclosure provides superior resistance to punctures when compared toEPS using the Slow Puncture Resistance Test Method as described in ASTMD-3763-86. The test results are shown in Tables 6-9 below.

Test Results

TABLE 6 Tested Insulative Cellular Non-Aromatic Polymeric MaterialElongation At Specimen # Peak Load g(f) Break (mm) 1 13876.49 — 213684.33 — 3 15121.53 — 4 15268.95 17 5 14970.47 20 6 13049.71 — 715648.44 17 8 15352.38 23 9 18271.37 — 10 16859.29 — Mean 15210.30 19Std. Dev. 1532.83  3

TABLE 7 Expanded Polystyrene Elongation At Specimen # Peak Load g(f)Break (mm) 1 2936.73 — 2 2870.07 10 3 2572.62 — 4 2632.44 — 5 2809.70 —6 2842.93 — 7 2654.55 — 8 2872.96 — 9 2487.63 — 10 2866.53 — 11 2803.25— 12 2775.22 — 13 2834.28 — 14 2569.97 — Mean 2752.06 10 Std. Dev.140.42 —

TABLE 8 Paper Wrapped Expanded Polystyrene Elongation At Specimen # PeakLoad g(f) Break (mm) 1 7930.61 — 2 10044.30 — 3 9849.01 — 4 8711.44 — 59596.79 — 6 9302.99 — 7 10252.27 — 8 7785.64 — 9 8437.28 — 10 6751.98 —11 9993.19 — Mean 8968.68 — Std. Dev. 1134.68 —

TABLE 9 Summary of Slow Puncture-Straw Test Results Sample ID Testedinsulative cellular non-aromatic Expanded Paper wrapped polymericmaterial cup polystyrene (mean) expanded polystyrene (mean) grams-force(gf) grams-force (gf) (mean) grams-force (gf) Average gf: 15210 27528969

Example 2—Formulation and Extrusion

The following formulation was used:

-   -   81.70% Borealis WB140HMS primary polypropylene    -   0.25% Amco A18035 PPRO talc filled concentrate    -   2% Ampacet 102823 Process Aid PE MB linear low density        polyethylene slip agent    -   0.05% Hydrocerol CF-40E chemical foaming agent    -   1% Colortech 11933-19 colorant    -   15% Braskem F020HC high crystallinity homopolymer polypropylene    -   3.4 lbs/hour of CO₂ was introduced into the molten resin.    -   Density of the sheet formed ranged from 0.155-0.182 g/cc

The formulation was added to an extruder hopper. The extruder heated theformulation to form a molten resin mixture. To this mixture was addedthe CO₂ to expand the resin and reduce density. The mixture thus formedwas extruded through a die head into a strip. The strip was then cut andformed into a cup.

Example 2—Test Results

Rigidity

Test Method

The test method is the same as described for rigidity testing in Example1.

Test Results

The rigidity test results are shown in Table 10 below.

TABLE 10 unlidded/filled 200° F. lidded/filled 200° F. Rigidities (kg's)Rigidities (kg's) 90° 90° Wall Sam- from Aver- from Aver- Gram Thick-ple# Seam Seam age Seam Seam age Weights ness B1 0.354 0.380 0.367 0.4700.528 0.499 12.6 0.0744 B2 0.426 0.464 0.445 0.598 0.610 0.604 13.0 B30.526 0.494 0.510 0.628 0.618 0.623 12.4 B4 0.592 0.566 0.579 0.7400.746 0.743 13.2 0.475 0.617 12.80 Density 0.1817Insulation

Test Method—Wall Temperature

A cup formed from the formulation noted above was used having a densityof 0.18 g/cm³ and a wall thickness of 0.074 inches (1.8796 mm). A hotliquid at 200° F. (93.3° C.) was placed in the cup.

Test Results

The temperature measured on the outside wall of the cup was about 151°F. (66.1° C.), i.e., a 49.0° F. (27.2° C.) drop. The maximum temperatureover a five-minute period was observed to peak at 151° F. (66.1° C.).

Insulation testing in the form of thermal conductivity was done.

Thermal Conductivity

Test Method

This test measures bulk thermal conductivity (W/m-K), measured atambient temperature and at 93° C. A ThermTest TPS 2500 S ThermalConstants Analyzer instrument was used, employing the test method ofISO/DIS 22007-2.2 and using the Low Density/High Insulating option. TheTPS sensor #5501 (6.403 mm radius) with Kapton® insulation was used forall measurements. A 20 second test was done, using 0.02 Watts power.Data using points 100-200 were reported.

Test Results

The test results shown in Table 11 below.

TABLE 11 Mean Thermal Conductivity Results Mean Thermal ConductivityStandard Deviation Temp. (° C.) (W/m-K) (W/m-K) 21 0.05792 0.00005 930.06680 0.00025

The present disclosure relates to a container. For the purposes ofnon-limiting illustration only, a cup is described in the exemplaryembodiments; however, the container may be embodied in any of a varietyof possible vessel shapes or structures or for a variety ofapplications, such as, but not limited to, a conventional beverage cup,storage container, bottle, or the like. For the purpose of nonlimitingillustration only, a liquid beverage will be used as the material whichcan be contained by the container; however, a container in accordancewith the present disclosure may hold liquids, solids, gels, combinationsthereof, foodstuffs, or other material.

A method of forming a vessel in accordance with the present disclosuremay include the steps of forming a blank for a side wall of the vessel,heating first and second portions of the blank, wrapping the blank suchthat the first and second portions overlap, and compressing theoverlapped portions while they are heated to secure the first and secondportions to form a side wall. The blank may include an insulativecellular non-aromatic polymeric material having a non-uniform densitywith areas of higher density formed in the blank to define depressionsin the blank.

In some embodiments, the method of forming a vessel may include thesteps of forming a floor blank for a floor of the vessel and placing thefloor blank adjacent a first end of the elongated wall, securing thefloor blank to the side wall, heating the floor blank prior to securingthe floor blank to the side wall, and heating a portion of the side wallwhich contacts the floor blank prior to securing the floor blank to theside wall. In some embodiments, the method of forming a vessel mayinclude the step of applying pressure to the floor blank and the portionof the side wall to secure the portion of the elongated wall with thefloor blank.

In some embodiments, the method of forming a vessel may include the stepof displacing a portion of the side wall that engages the floor blank towrap the portion of the side wall around a portion of the floor blank.In some embodiments, the method of forming a vessel may include the stepof compressing a portion of the side wall to increase the localizeddensity of the compressed portion to define a fold line about which thedisplaced portion of the side wall is displaced.

In some embodiments, the method of forming a vessel may include thesteps of heating the entire blank for a side wall to anneal the blankand allowing the blank to cool before heating first and second portionsof the blank. In some embodiments, the method of forming a vessel mayinclude the steps of forming a composite including an insulativecellular non-aromatic polymeric material, and at least one polymericfilm adhered to the insulative cellular non-aromatic polymeric material,and forming the blank for the elongated wall of the vessel from thecomposite.

In some embodiments, the at least one polymeric film may includebiaxially oriented polypropylene. In some embodiments, the method offorming a vessel may include the step of heating composite prior toforming the blank for a side wall to release stresses in the biaxiallyoriented polypropylene film. In some embodiments, the method of forminga vessel may include the step of applying adhesive to the floor blankprior to securing the blank to the side wall.

In some embodiments, the method of forming a vessel may include thesteps of applying adhesive to a portion of the elongated wall whichcontacts the floor blank prior to securing the floor blank to theelongated wall, applying pressure to the floor blank and the portion ofthe side wall to secure the portion of the elongated wall with the floorblank, displacing a portion of the elongated wall that engages the floorblank to wrap the portion of the elongated wall around a portion of thefloor blank, and compressing a portion of the elongated wall to increasethe localized density of the compressed portion to define a fold lineabout which the displaced portion of the elongated wall is displaced.

The invention claimed is:
 1. An insulative cup comprising a bodyincluding a sleeve-shaped side wall and a floor coupled to the body todefine an interior region bounded by the sleeve-shaped side wall and thefloor, wherein the body comprises a sheet comprising insulative cellularnon-aromatic polymeric material configured to provide means for enablinglocalized plastic deformation in at least one selected region of thebody to provide a plastically deformed first material segment having afirst density located in a first portion of the selected region of thebody and a second material segment having a second density lower thanthe first density located in an adjacent second portion of the selectedregion of the body without fracturing the insulative cellularnon-aromatic polymeric material so that a predetermined insulativecharacteristic is maintained in the body, wherein the plasticallydeformed first material segment is cellular and the second materialsegment is cellular, wherein a first of the selected regions of the bodyin which localized plastic deformation is enabled by the insulativecellular non-aromatic polymeric material is in the sleeve-shaped sidewall and wherein the sleeve-shaped side wall includes an upright innertab arranged to extend upwardly from the floor and configured to providethe first material segment having the first density in the first of theselected regions of the body, an upright outer tab arranged to extendupwardly from the floor and to mate with the upright inner tab along aninterface therebetween, and an upright fence arranged to interconnectthe upright inner and outer tabs and surround the interior region andconfigured to provide the second material segment having the seconddensity in the first of the selected regions of the body and cooperatewith the upright inner and outer tabs to form the sleeve-shaped sidewall, wherein a second of the selected regions of the body in whichlocalized plastic deformation is enabled by the insulative cellularnon-aromatic polymeric material is in a rolled brim included in the bodyand coupled to an upper end of the sleeve-shaped side wall to lie inspaced-apart relation to the floor and to frame an opening into theinterior region and wherein the rolled brim includes an inner rolled tabconfigured to provide the first material segment in the second of theselected regions of the body and coupled to an upper end of the uprightouter tab included in the sleeve-shaped side wall, an outer rolled tabcoupled to an upper end of the upright inner tab included in thesleeve-shaped side wall and to an outwardly facing exterior surface ofthe inner rolled tab, and a rolled lip arranged to interconnectoppositely facing side edges of each of the inner and outer rolled tabsand configured to provide the second material segment having the seconddensity in the second of the selected region of the body and cooperatewith the inner and outer rolled tabs to form the rolled brim, wherein athird of the selected regions of the body in which localized plasticdeformation is enabled by the insulative cellular non-aromatic polymericmaterial is in a floor mount included in the body and coupled to a lowerend of the sleeve-shaped side wall to lie in spaced-apart relation tothe rolled brim and to the floor to support the floor in a stationaryposition relative to the sleeve-shaped side wall to form the interiorregion and wherein the floor mount includes a web-support ring coupledto the lower end of the sleeve-shaped side wall and configured toprovide the second material segment having the second density in thethird of the selected regions of the body, a floor-retaining flangecoupled to the floor and arranged to be surrounded by the web-supportring, and a web arranged to interconnect the floor-retaining flange andthe web-support ring and configured to provide the first materialsegment having the first density in the third of the selected regions ofthe body, wherein a fourth of the selected regions of the body in whichlocalized plastic deformation is enabled by the insulative cellularnon-aromatic polymeric material is in the floor-retaining flange of thefloor mount, the floor-retaining flange includes an alternating seriesof upright thick and thin staves arranged in side-to-side relation toextend upwardly from the web toward the interior region bounded by thesleeve-shaped side wall and the floor, a first of the upright thickstaves is configured to include a right side edge extending upwardlyfrom the web toward the interior region, a second of the upright thickstaves is configured to include a left side edge arranged to extendupwardly from the web toward the interior region and lie in spaced-apartconfronting relation to the right side edge of the first of the uprightthick staves, and a first of the upright thin staves is arranged tointerconnect the right side edge of the first of the upright thickstaves and the left side edge of the second of the upright thick stavesand to cooperate with the left and right side edges to definetherebetween a vertical channel, the first of the upright thin staves isconfigured to provide the first material segment in the fourth of theselected regions of the body, and the first of the upright thick stavesis configured to provide the second material segment in the fourth ofthe selected regions of the body.
 2. The insulative cup of claim 1,wherein the upright fence includes an upright left side edge and anupright right side edge arranged to lie in spaced-apart confrontingrelation to the upright left side edge and the upright outer tab isconfigured to have the first density and mate with the upright inner tabto establish a bridge arranged to interconnect the upright left andright side edges of the upright fence and formed of plastically deformedmaterial having the first density.
 3. The insulative cup of claim 2,wherein the upright fence has an inner surface bounding a portion of theinterior region and an outer surface facing away from the interiorregion and surrounding the inner surface of the upright fence andcooperating with the inner surface of the upright fence to define afirst thickness therebetween, the upright inner tab includes an innersurface bounding a portion of the interior region and an outer surfacefacing toward the upright outer tab, the upright outer tab includes aninner surface facing toward the interior region and mating with theouter surface of the upright inner tab to define the interface betweenthe upright inner and outer tabs, and the upright outer tab furtherincludes an outer face facing away from the upright inner tab, the innerand outer surfaces of the upright inner tab cooperate to define a secondthickness therebetween that is about half of the first thickness, andthe inner and outer surfaces of the upright outer tab cooperate todefine a third thickness that is about half of the first thickness. 4.The insulative cup of claim 1, wherein each of the web and theweb-support ring has an annular shape.
 5. The insulative cup of claim 1,wherein each of the floor-retaining flange, the web, and the web-supportring includes an inner layer having an interior surface mating with thefloor and an overlapping outer layer mating with an exterior surface ofthe inner layer.
 6. The insulative cup of claim 1, wherein the floorincludes a horizontal platform bounding a portion of the interior regionand a platform-support member coupled to the horizontal platform andarranged to extend downwardly away from the interior region into a spaceprovided between the floor-retaining flange and the web-support ring tomate with each of the floor-retaining flange and the web-support ring.7. The insulative cup of claim 6, wherein the platform-support memberhas an annular shape and is arranged to surround the floor-retainingflange and lie in an annular space provided between the horizontalplatform and the web.
 8. The insulative cup of claim 6, wherein each ofthe floor-retaining flange, the web, and the web-support ring includesan inner layer having an interior surface mating with the floor and anoverlapping outer layer mating with an exterior surface of the innerlayer and the inner layer of each of the floor-retaining flange, theweb, and the web-support ring is arranged to mate with theplatform-support member.
 9. The insulative cup of claim 1, wherein theinsulative cellular non-aromatic polymeric materials comprises apolypropylene base resin having a high melt strength, a polypropylenehomopolymer resin, at least one nucleation agent, and gas means forexpanding the resins to reduce density.
 10. An insulative cup comprisinga body including a sleeve-shaped side wall and a floor coupled to thebody to define an interior region bounded by the sleeve-shaped side walland the floor, wherein the body comprises a sheet comprising insulativecellular non-aromatic polymeric material configured to provide means forenabling localized plastic deformation in at least one selected regionof the body to provide a plastically deformed first material segmenthaving a first density located in a first portion of the selected regionof the body and a second material segment having a second density lowerthan the first density located in an adjacent second portion of theselected region of the body without fracturing the insulative cellularnon-aromatic polymeric material so that a predetermined insulativecharacteristic is maintained in the body, wherein the plasticallydeformed first material segment is cellular and the second materialsegment is cellular, wherein the body further includes a rolled brimcomprising the insulative cellular non-aromatic polymeric material, therolled brim is coupled to an upper end of the sleeve-shaped side wall tolie in spaced-apart relation to the floor and to frame an opening intothe interior region, and the rolled brim includes an inner rolled tabconfigured to provide the plastically deformed first material segmenthaving the first density and to include oppositely facing left and rightside edges and a rolled lip arranged to interconnect the oppositelyfacing left and right side edges of the inner rolled tab and configuredto provide the second material segment having the second density,wherein the body further includes a floor-retaining flange comprisingthe insulative cellular non-aromatic polymeric material and wherein thefloor-retaining flange is coupled to the floor and is formed to includean alternating series of upright thick and thin staves arranged inside-to-side relation to extend upwardly toward the interior regionbounded by the sleeve-shaped side wall and the floor, a first of theupright thick staves is configured to include a right side edgeextending upwardly toward the interior region, a second of the uprightthick staves is configured to include a left side edge extendingupwardly toward the interior region and lie in spaced-apart confrontingrelation to the right-side edge of the first of the upright thickstaves, and a first of the upright thin staves is arranged tointerconnect the left and right side edges to define therebetween avertical channel, the first of the upright thin staves is configured toprovide the plastically deformed first material segment, and the firstof the upright thick staves is configured to provide the second materialsegment.
 11. The insulative cup of claim 10, wherein the rolled brimfurther includes an outer rolled tab coupled to an outwardly facingsurface of the inner rolled tab to provide an outer shell covering theinner rolled tab and formed of plastically deformed material having thefirst density.
 12. The insulative cup of claim 10, wherein the bodyfurther includes a sleeve-shaped side wall comprising the insulativecellular non-aromatic polymeric material and the sleeve-shaped side wallincludes an upright inner tab arranged to extend upwardly from the floorand configured to provide the plastically deformed first materialsegment having the first density, an upright outer tab arranged toextend upwardly from the floor and to mate with the upright inner tabalong an interface therebetween, and an upright fence arranged tointerconnect the upright inner and outer tabs and surround the interiorregion and configured to provide the second material segment having thesecond density.
 13. The insulative cup of claim 10, wherein the bodyfurther includes a floor mount comprising the insulative cellularnon-aromatic polymeric material and the floor mount includes aweb-support ring coupled to a lower end of the sleeve-shaped side walland configured to provide the second material segment having the seconddensity, a floor-retaining flange coupled to the floor and arranged tobe surrounded by the web-support ring, and a web arranged tointerconnect the floor-retaining flange and the web-support ring andconfigured to provide the plastically deformed first material segmenthaving the first density.
 14. The insulative cup of claim 10, whereinthe body further includes a floor mount comprising the insulativecellular non-aromatic polymeric material, the floor mount is coupled toa lower end of the sleeve-shaped side wall and to the floor to supportthe floor in a stationary position relative to the sleeve-shaped sidewall to form the interior region, and the floor mount includes afloor-retaining flange coupled to the floor, a web-support ring coupledto the lower end of the sleeve-shaped side wall and arranged to surroundthe floor-retaining flange, and a web arranged to interconnect thefloor-retaining flange and the web-support ring and configured toprovide the plastically deformed first material segment having the firstdensity, and the web-support ring is configured to provide the secondmaterial segment having the second density.
 15. The insulative cup ofclaim 14, wherein each of the web and the web-support ring has anannular shape.
 16. The insulative cup of claim 14, wherein each of thefloor-retaining flange, the web, and the web-support ring includes aninner layer having an interior surface mating with the floor and anoverlapping outer layer mating with an exterior surface of the innerlayer.
 17. The insulative cup of claim 14, wherein the floor includes ahorizontal platform bounding a portion of the interior region and aplatform-support member coupled to the horizontal platform and arrangedto extend downwardly away from the interior region into a space providedbetween the floor-retaining flange and the web-support ring to mate witheach of the floor-retaining flange and the web-support ring.
 18. Theinsulative cup of claim 17, wherein the platform-support member has anannular shape and is arranged to surround the floor-retaining flange andlie in an annular space provided between the horizontal platform and theweb.
 19. The insulative cup of claim 17, wherein each of thefloor-retaining flange, the web, and the web-support ring includes aninner layer having an interior surface mating with the floor and anoverlapping outer layer mating with an exterior surface of the innerlayer and the inner layer of each of the floor-retaining flange, theweb, and the web-support ring is arranged to mate with theplatform-support member.